jcb 2DXL, Service Manual

Page 1: ...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 ope...

Page 2: ...9813 5500 1 Notes Find manuals at https best manuals com...

Page 3: ...3 5500 1 SERVICE MANUAL Volume 1 2DXL EN 9813 5500 SERVICE MANUAL Volume 2 2DXL EN 9813 5500 SERVICE MANUAL Volume 3 2DXL EN 9813 5500 SERVICE MANUAL Volume 4 2DXL EN 9813 5500 Find manuals at https b...

Page 4: ...Notes 9813 5500 1 Find manuals at https best manuals com...

Page 5: ...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 01 11 01 03 27 Maintenance Positions 01 12 01 09 Description 01 09 1...

Page 6: ...Notes 9813 5500 1 2015 12 31 Find manuals at https best manuals com...

Page 7: ...y 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 Assessme...

Page 8: ...Notes 01 2 9813 5500 1 01 2 Find manuals at https best manuals com...

Page 9: ...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 All the time...

Page 10: ...ion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word N...

Page 11: ...are of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile...

Page 12: ...ucted Do not use Triochloroethane or paint thinners near O rings and seals Arc Welding To prevent the possibility of damage to electronic components disconnect the battery and the alternator before ar...

Page 13: ...onent or surrounding area Used fluoroelastomeric components subjected to temperatures greater than 300 C e g engine fire must be treated using the following safety procedure Make sure that heavy duty...

Page 14: ...r bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extension If you begin to feel drowsy stop the...

Page 15: ...configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and feet inside the machine When u...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...p the engine and remove the ignition key 5 Disconnect the battery to prevent accidental operation of the engine 6 If necessary put chocks against the two sides of the wheels before you get below the m...

Page 19: ...the lift arms are supported by the safety strut Removing the Lift Arm Safety Strut 1 Fully raise the lift arms to take the weight off the safety strut 2 Stop the engine and remove the ignition key 3...

Page 20: ...correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not using electrical power If you do not take these precaution...

Page 21: ...01 Machine 09 Description 01 15 9813 5500 1 01 15 09 Description Contents Page No 01 09 12 Main Component Locations 01 17 01 09 15 Service Point Locations 01 19...

Page 22: ...Notes 01 16 9813 5500 1 01 16...

Page 23: ...01 Machine 09 Description 12 Main Component Locations 01 17 9813 5500 1 01 17 12 Main Component Locations Component Identification Figure 5 B A C D Figure 6 H E F G...

Page 24: ...01 Machine 09 Description 12 Main Component Locations 01 18 9813 5500 1 01 18 A Lift arm B Battery compartment C Canopy D Fuel tank E Safety strut F Counterweight G Rear hitch H Hydraulic tank...

Page 25: ...01 19 9813 5500 1 01 19 15 Service Point Locations Introduction Engine Compartment Figure 7 A C D E F B A Air filter assembly B Coolant expansion bottle C Fuel filter water separator D Engine fuel fi...

Page 26: ...cription 15 Service Point Locations 01 20 9813 5500 1 01 20 Right Side Figure 8 A B A Window washer fluid filler point B Fuel filler point Left Side Figure 9 B A A Hydraulic level indicator B Hydrauli...

Page 27: ...01 Machine 33 Cleaning 01 21 9813 5500 1 01 21 33 Cleaning Contents Page No 01 33 00 General 01 23...

Page 28: ...Notes 01 22 9813 5500 1 01 22...

Page 29: ...he machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures that re...

Page 30: ...t aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and o...

Page 31: ...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 Ge...

Page 32: ...Notes 9813 5500 1 2016 01 04...

Page 33: ...03 Attachments 00 General 03 1 9813 5500 1 03 1 00 General Contents Page No 03 00 00 General 03 3...

Page 34: ...Notes 03 2 9813 5500 1 03 2...

Page 35: ...hich it is safe to operate or the safe distance from power lines Practice using attachments off the job before working with them for the first time JCB attachments are designed and manufactured specif...

Page 36: ...ly on the machines for which they were designed WARNING Load and unload on firm level ground Always be alert for possible hazards Take special care when turning or reversing DANGER Before lowering the...

Page 37: ...axoyl contains turpentine substitute which is flammable Keep flames away when applying Waxoyl Waxoyl can take a few weeks to dry completely Keep flames away during the drying period Do not weld near t...

Page 38: ...03 Attachments 09 Lift Arm Quickhitch 03 6 9813 5500 1 03 6 09 Lift Arm Quickhitch Contents Page No 03 09 00 General 03 7...

Page 39: ...ls 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 th...

Page 40: ...03 Attachments 30 Shovel 03 8 9813 5500 1 03 8 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...

Page 41: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...