jcb 210X Service Manual
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SERVICE MANUAL
EXCAVATOR
210X, 220X
EN - 9813/9600 - ISSUE 2 - 02/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb 210X

  • Page 1 Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/9600-2 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 210X, 220X 210X, 220X EN 9813/9600 EN 9813/9600 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 210X, 220X 210X, 220X EN 9813/9600 EN 9813/9600 9813/9600-2 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/9600-2 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary Auxiliary Relief Valve Charge Air Cooler Diesel Exhaust Fluid Electronic Control Unit FEAD Front End Accessory Drive HVAC Heating Ventilation Air Conditioning Main Relief Valve Parts Identification List Personal Protective Equipment Selective Catalytic Reduction 9813/9600-2 2018-01-31 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - Yours and Others ....................01-3 01-03-06 Safety Warnings ....................... 01-4 01-03-09 General Safety ......................... 01-5 01-03-12 Maintenance Safety ......................01-6 01-03-18 Operating Safety ......................01-8 01-03-21 Worksite Safety ......................
  • Page 8 Notes: 01 - 2 9813/9600-2 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them. Safety is not just a matter of responding to the warnings.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Maintenance Position (Excavator Arm Lowered) 1. Park the machine on solid, level ground, with the upper structure parallel to the undercarriage. 2. If applicable, lower the dozer blade. 3.
  • Page 19: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-15 01-06-06 Using the Manual ......................01-16 01 - 13 9813/9600-2 01 - 13...
  • Page 20 Notes: 01 - 14 9813/9600-2 01 - 14...
  • Page 21: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: 210X 2500051 220X 2500051...
  • Page 22: Using The Manual

    ............ 01-16 Information in this manual conforms to a standard Fault-Finding ..........01-18 JCB service manual format. The format uses section headings taken from a PIL (Parts Identification List). These headings are assigned numerical identification references. Table 1. Example Section...
  • Page 23 After Sales Some procedures require the use of equipment such as special tools and PPE (Personal Protective Equipment). Where special tools are available from JCB the applicable part numbers are given in the 01 - 17 9813/9600-2 01 - 17...
  • Page 24 01 - Machine 06 - About this Manual 06 - Using the Manual Fault-Finding Fault Engine does not start / stop Table 2. Page 01-18 Engine performance is not as expected Table 3. Page 01-18 Hydraulic services do not operate Table 4.
  • Page 25 01 - Machine 06 - About this Manual 06 - Using the Manual Cause Remedy Two stage MRV (Main Relief Valve) system fault Refer to Check (Pressure) (PIL 30-50-03) (boost function) Refer to (PIL 33-27-37) Cylinder ram fault Refer to Fault Finding (PIL 30-15-00) (1) Check the applicable hydraulic service cycle times.
  • Page 26: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-21 01-09-15 Service Point Locations ....................01-22 01 - 20 9813/9600-2 01 - 20...
  • Page 27: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Main Assemblies Figure 3. A Bucket (attachment) B Tipping link C Bucket ram D Dipper E Tipping lever F Dipper ram G Boom H Boom ram J Operator station K Counterweight...
  • Page 28: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Service Points - Hydraulics Figure 4. Upper structure A Breather - hydraulic tank B Cover - suction strainer C Cover - drain line filter D Cover - main filter E Oil drain plug - slew motor gearbox (access F Oil filler port - slew motor gearbox (if applicable)
  • Page 29 01 - Machine 09 - Description 15 - Service Point Locations Figure 5. Hydraulic compartment A Hydraulic pump compartment B Servo filter element C Level gauge - hydraulic oil tank Figure 6. Cooling bay A Cooling bay B Hydraulic oil cooler (cooling pack) C Hydraulic oil cooler drain plug 01 - 23 9813/9600-2...
  • Page 30 01 - Machine 09 - Description 15 - Service Point Locations Service Points - Engine Figure 7. Upper structure A Filter - refuel pump (inside toolbox) B Filter - DEF (Diesel Exhaust Fluid) pump supply module (inside toolbox) C Filler port DEF tank (inside toolbox) D Exhaust clamp - DEF dosing module E Exhaust clamp - SCR (Selective Catalytic F Exhaust silencer...
  • Page 31 01 - Machine 09 - Description 15 - Service Point Locations Figure 8. Battery / cooling compartment A Battery compartment B Cooling compartment C Induction air filter (outer) D Induction air filter (inner) E Induction inlet grill F Scavenge intake G CAC (Charge Air Cooler) (cooling pack) H Engine coolant radiator (cooling pack) J Fuel cooler...
  • Page 32 01 - Machine 09 - Description 15 - Service Point Locations Figure 9. Hydraulic compartment A Hydraulic pump compartment B Fuel lubricity filter (if installed) C Fuel pre-filter and water separator D Fuel line isolator valve E Water separator (if installed) F Fuel tank water drain off valve G Engine oil filter H Engine fuel filter...
  • Page 33 01 - Machine 09 - Description 15 - Service Point Locations Service Points - Heating and Ventilation System Figure 10. A Cooling compartment B High pressure recharge point (air conditioning only) C Low pressure recharge point (air conditioning D Condenser radiator (air conditioning only) only) E Fresh air filter F Recirculation filter...
  • Page 34 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-29 01 - 28 9813/9600-2 01 - 28...
  • Page 35 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-29 or other chemicals, you must adhere to Preparation ............ 01-30 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 36 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 37 03 - Attachments, Couplings and Load Handling Contents Page No. 03-00 Attachments 03-00-00 General ..........................03-3 03-10 Excavator End Quickhitch 03-10-06 Hydraulic Quickhitch ......................03-7 9813/9600-2 2017-10-02...
  • Page 38 Notes: 9813/9600-2 2017-10-02...
  • Page 39 03 - Attachments, Couplings and Load Handling 00 - Attachments 00 - Attachments Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/9600-2 03 - 1...
  • Page 40 Notes: 03 - 2 9813/9600-2 03 - 2...
  • Page 41: Attachments, Couplings And Load Handling

    03-3 A wide range of optional attachments are available Health and Safety ........... 03-4 to increase the versatility of your machine. Only JCB approved attachments are recommended for use Check (Condition) ..........03-4 with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 42: Attachments

    Check (Condition) Attachments Purpose Tests Lifting Use only the JCB approved attachments that are Equipment specified for your machine. Operating with non- specified attachments can overload the machine, All lifting equipment (for example forks, lifting hooks causing possible damage and machine instability and shackles) requires inspection and testing by a which could result in injury to yourself or others.
  • Page 43: Excavator End Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 10 - Excavator End Quickhitch Contents Page No. 03-10-06 Hydraulic Quickhitch ......................03-7 03 - 5 9813/9600-2 03 - 5...
  • Page 44 Notes: 03 - 6 9813/9600-2 03 - 6...
  • Page 45: Hydraulic Quickhitch

    03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch 06 - Hydraulic Quickhitch Introduction Introduction ............03-7 The hydraulic quickhitch is installed in place of a Operation ............03-8 normal attachment at the dipper and tipping link. A hydraulically operated latch mechanism enables quickhitch compatible attachments to be installed and removed without the need to leave the cab.
  • Page 46 03 - Attachments, Couplings and Load Handling 10 - Excavator End Quickhitch 06 - Hydraulic Quickhitch Operation The quickhitch latch system is operated by springs and a double acting hydraulic ram. Spring pressure ensures that the latch defaults to the locked position. A remote solenoid control valve is energised by the electronic control system when the quickhitch is set to unlock.
  • Page 47 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-06 Moveable Panel and Cover 06-06-00 General ..........................06-3 06-06-03 Battery Compartment ....................... 06-4 06-06-06 Engine Compartment ....................... 06-6 06-06-07 Cooling Compartment ...................... 06-8 06-06-09 Hydraulic Compartment ....................06-10 06-06-30 Undershield ........................
  • Page 48 Acronyms Glossary DECU Display Electronic Control Unit Diesel Exhaust Fluid Dial Test Indicator FOPS Falling Object Protective Structure Light Emitting Diode MECU Machine Electronic Control Unit Printed Circuit Board Product Identification Number ROPS Roll-Over Protective Structure TOPS Tip-Over Protective Structure 9813/9600-2 2018-01-15...
  • Page 49 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Moveable Panel and Cover Contents Page No. 06-06-00 General ..........................06-3 06-06-03 Battery Compartment ....................... 06-4 06-06-06 Engine Compartment ....................... 06-6 06-06-07 Cooling Compartment ...................... 06-8 06-06-09 Hydraulic Compartment ....................
  • Page 50 Notes: 06 - 2 9813/9600-2 06 - 2...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

220x

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