jcb 2DXL Service Manual
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SERVICE MANUAL
2DXL
EN - 9813/5500 - ISSUE 1 - 01/2016
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2016 © 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
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brakes
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

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Summary of Contents for jcb 2DXL

  • 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: 9813/5500-1 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 2DXL 2DXL EN 9813/5500 EN 9813/5500 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 2DXL 2DXL EN 9813/5500 EN 9813/5500 9813/5500-1 Find manuals at https://best-manuals.com...
  • Page 4 Notes: 9813/5500-1 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. 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 ......................01-10 01-03-24 Risk Assessment ......................
  • Page 6 Notes: 9813/5500-1 2015-12-31 Find manuals at https://best-manuals.com...
  • Page 7: Safety

    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 9813/5500-1 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety - Yours And Others

    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 and on the product, 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

    People can be killed or injured on systems incorporating accumulators, the system if these precautions are not taken. pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may Repairs cause injury.
  • Page 13 01 - Machine 03 - Safety 12 - Maintenance Safety Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®. Fluoroelastomeric materials subjected high temperatures produce highly corrosive hydrofluoric acid. This acid can severely burn.
  • 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 Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-14 maintenance procedure. You can complete most of the maintenance procedures with the lift arm lowered.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions 4.2. Secure the strut in position with strap. 2. Stop the engine and remove the ignition key. 5. Lower the lift arm onto the strut. 3. Remove the strut. 5.1. Start the engine and slowly lower the 3.1.
  • Page 20 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 21: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-17 01-09-15 Service Point Locations ....................01-19 01 - 15 9813/5500-1 01 - 15...
  • Page 22 Notes: 01 - 16 9813/5500-1 01 - 16...
  • Page 23: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Component Identification Figure 5. Figure 6. 01 - 17 9813/5500-1 01 - 17...
  • Page 24 01 - Machine 09 - Description 12 - Main Component Locations A Lift arm B Battery compartment C Canopy D Fuel tank E Safety strut F Counterweight G Rear hitch H Hydraulic tank 01 - 18 9813/5500-1 01 - 18...
  • Page 25: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Engine Compartment Figure 7. A Air filter assembly B Coolant expansion bottle C Fuel filter/water separator D Engine fuel filter E Engine oil dipstick F Engine oil filler point 01 - 19 9813/5500-1...
  • Page 26 01 - Machine 09 - Description 15 - Service Point Locations Right Side Figure 8. A Window washer fluid filler point B Fuel filler point Left Side Figure 9. A Hydraulic level indicator B Hydraulic oil filler cap 01 - 20 9813/5500-1 01 - 20...
  • Page 27 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-23 01 - 21 9813/5500-1 01 - 21...
  • Page 28 Notes: 01 - 22 9813/5500-1 01 - 22...
  • Page 29 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-23 or other chemicals, you must adhere to Preparation ............ 01-24 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 30 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. is to be washed using a high pressure system. Make sure that the alternator, starter motor and 2.
  • Page 31 03 - Attachments Contents Page No. 03-00 General 03-00-00 General ..........................03-3 03-09 Lift Arm Quickhitch 03-09-00 General ..........................03-7 03-30 Shovel 03-30-00 General ..........................03-9 03-30-12 6-in-1 ..........................03-13 03-30-90 Teeth ..........................03-16 03-48 Rockbreaker 03-48-00 General ........................... 03-19 03-54 Auger 03-54-00 General ...........................
  • Page 32 Notes: 9813/5500-1 2016-01-04...
  • Page 33 03 - Attachments 00 - General 00 - General Contents Page No. 03-00-00 General ..........................03-3 03 - 1 9813/5500-1 03 - 1...
  • Page 34 Notes: 03 - 2 9813/5500-1 03 - 2...
  • Page 35 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 Lubricate ............03-4 with your machine. Consult your JCB Distributor for the full list of approved attachments available.
  • Page 36 Health and Safety Lubricate Attachments Where applicable, refer to the specific manufacturers Use only the JCB approved attachments that are manual for instructions on the lubrication of optional specified for your machine. Operating with non- attachments. specified attachments can overload the machine, Apply grease to all the points and linkages.
  • Page 37 03 - Attachments 00 - General 00 - General Excavator Arm Quickhitch (Hydraulic) Figure 14. Figure 12. Power Sideshift Figure 13. Knuckle (If Installed) CAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely.
  • Page 38 03 - Attachments 09 - Lift Arm Quickhitch 09 - Lift Arm Quickhitch Contents Page No. 03-09-00 General ..........................03-7 03 - 6 9813/5500-1 03 - 6...
  • Page 39 03 - Attachments 09 - Lift Arm Quickhitch 00 - General 00 - General Introduction Quickhitches are used on machines to allow the rapid change of buckets, shovels and other attachments on the machine. Quickhitches do not normally have a specific function themselves in that they do not carry out handling or digging operations, but when installed on a machine they become a part of the overall machine system.
  • Page 40 03 - Attachments 30 - Shovel 30 - Shovel Contents Page No. 03-30-00 General ..........................03-9 03-30-12 6-in-1 ..........................03-13 03-30-90 Teeth ..........................03-16 03 - 8 9813/5500-1 03 - 8...
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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