service repair manual

1. 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

2. 18 - Fuel and Exhaust System
24 - Exhaust
00 - General
18 - 25 9813/5500-1 18 - 25
00 - General
Introduction .................................................... 18-25
Health and Safety .......................................... 18-26
Check (Condition) .......................................... 18-26
Introduction
The exhaust system is used to guide exhaust gases
away from the controlled combustion inside the
engine by means of an exhaust pipe. Depending
on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.
• Turbocharger to increase the engine power (if
installed).
• A catalytic converter or EGR (Exhaust Gas
Recirculation) system to reduce air pollution (if
installed).
• SCR (Selective Catalytic Reduction) (if
installed). In SCR system exhaust gases
pass through the DEF (Diesel Exhaust Fluid)
injection chamber to lower the NOx (Nitrogen
Oxide) concentration in the exhaust gases.
• A silencer or muffler to reduce noise (if
installed).
The exhaust pipe carries the toxic and noxious gases
away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.

3. 18 - Fuel and Exhaust System
24 - Exhaust
00 - General
18 - 26 9813/5500-1 18 - 26
Health and Safety
Exhaust Gases
Machine exhaust gases can harm and possibly kill
you or 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 machine at once and get into fresh air.
Sparks
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
Check (Condition)
Excessive smoke from the exhaust stack combined
with a complaint of low power could be as a result of:
• Dirt or dust (unfiltered air) ingested directly into
the engine, resulting in damage to the cylinder
bores, there will also be a possible increase in
oil consumption.
• Air leaks from the air hose connections.
• Exhaust manifold leaks.

4. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 27 9813/5500-1 18 - 27
03 - Inlet Manifold
Introduction .................................................... 18-27
Check (Condition) .......................................... 18-28
Introduction
On compression ignition (diesel) engines, the inlet
manifold (also called the intake manifold) is the
part of the air intake system that distributes air for
combustion to the cylinders via each inlet port in
the cylinder head. The design of the manifold is
important to make sure that air is distributed as
evenly as possible under all engine speed and load
conditions.

5. 18 - Fuel and Exhaust System
24 - Exhaust
03 - Inlet Manifold
18 - 28 9813/5500-1 18 - 28
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.

6. 18 - Fuel and Exhaust System
24 - Exhaust
04 - Outlet Manifold
18 - 29 9813/5500-1 18 - 29
04 - Outlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.

7. 18 - Fuel and Exhaust System
96 - Fuel Pipe
18 - 30 9813/5500-1 18 - 30
96 - Fuel Pipe
Contents Page No.
18-96-00 General ........................................................................................................................... 18-31

8. 18 - Fuel and Exhaust System
96 - Fuel Pipe
00 - General
18 - 31 9813/5500-1 18 - 31
00 - General
Introduction .................................................... 18-31
Health and Safety .......................................... 18-32
Component Identification ............................... 18-32
Introduction
Important: The high pressure fuel pipes must be
replaced every time they are removed. If you install
the original pipes, it will cause leaks at the fuel pipe
connections.
High Pressure Pipe
The high pressure pipes are thick walled and
seamless tubes made of steel. The high pressure
fuel pipes supply pressurised fuel from the high
pressure fuel pump to the fuel rail. From the rail, fuel
is supplied to the electronic injectors through the high
pressure pipes.
The ends of the tubes are formed with conical nipples
for proper installation in the sealing cones on the fuel
rail and on the injector port.
Low Pressure Pipe
During fuel injection some fuel bleeds off the
electronic injectors and is sent back to the tank
through the low pressure pipes. The return fuel
from the high pressure fuel pump is also transferred
through the low pressure pipe.
All the low pressure return fuel is collected at a
common fuel distributor and is sent to the tank
through the low pressure pipes.
The low pressure fuel pipe also supplies low
pressure fuel from the tank to the high pressure pump
through the fuel filter.

9. 18 - Fuel and Exhaust System
96 - Fuel Pipe
00 - General
18 - 32 9813/5500-1 18 - 32
Health and Safety
WARNING Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel
system. Before disconnecting any part of the fuel
system, thoroughly clean around the connection.
When a component has been disconnected, for
example a fuel pipe, always fit protective caps
and plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
Component Identification
Refer to Fuel System- Component Identification (PIL
18-00).

10. 9813/5500-1
2016-01-01
21 - Cooling System
Contents Page No.
Acronyms Glossary .................................................................................................................................... 21-2
21-00 General
21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-11
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-15
21-09 Pump
21-09-00 General ........................................................................................................................... 21-17
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-19
21-93 Hose
21-93-00 General ........................................................................................................................... 21-25

11. 9813/5500-1
2016-01-01
Acronyms Glossary
ECM Engine Control Module

12. 21 - Cooling System
00 - General
21 - 1 9813/5500-1 21 - 1
00 - General
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3

13. Notes:
21 - 2 9813/5500-1 21 - 2

14. 21 - Cooling System
00 - General
00 - General
21 - 3 9813/5500-1 21 - 3
00 - General
Introduction ...................................................... 21-3
Health and Safety ........................................... 21-4
Fault-Finding .................................................... 21-5
Drain and Fill ................................................... 21-7
Check (Leaks) ................................................. 21-7
Check (Level) .................................................. 21-8
Introduction
During the working cycle of the engine a great deal
of heat is generated. It is important that the engine is
kept at its normal operating temperature to achieve
maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
quickly and then maintain it.

15. 21 - Cooling System
00 - General
00 - General
21 - 4 9813/5500-1 21 - 4
Health and Safety
CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the
cap, hot coolant can spray out and burn you.
Make sure that the engine is cool before you work
on the cooling system.
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full
strength or diluted antifreeze.

16. 21 - Cooling System
00 - General
00 - General
21 - 5 9813/5500-1 21 - 5
Fault-Finding
Fault
Coolant - Loss. Table 8. Page 21-5
Coolant - Over Temperature. Table 9. Page 21-5
Coolant - Under Temperature. Table 10. Page 21-6
Coolant - Contaminated. Table 11. Page 21-6
Table 8. Coolant - Loss.
Cause Remedy
Incorrect coolant level. Check the level.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting
in loss through the radiator overflow.
See Also: Table 9. Coolant - Over Temperature.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
Table 9. Coolant - Over Temperature.
Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 8. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or
incorrectly routed (sudden overheating).
Check routing and operation or vent line.

17. 21 - Cooling System
00 - General
00 - General
21 - 6 9813/5500-1 21 - 6
Cause Remedy
Leak between the top tank and the auxiliary tank
(sudden overheating).
Check for coolant leakage between radiator auxiliary
tank and radiator top tank.
Cooling passages in radiator, cylinder head, head
gasket or crankcase blocked.
Flush the system and fill with clean coolant.
ECM (Engine Control Module) or electrical sensor
fault.
Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
Table 10. Coolant - Under Temperature.
Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 11. Coolant - Contaminated.
Cause Remedy
Coolant rusty, operation without correct mixture of
antifreeze and water.
Drain and flush the cooling system. Fill with correct
mixture of antifreeze and water. Review the coolant
change interval.
Engine oil cooler, or cooler housing allowing cross
contamination of coolant with engine oil.
Remove the oil cooler assembly and check relevant
sealing elements for damage.
Transmission lubricating oil cooler leaking (if
applicable).
Check/replace lubricating oil cooler. Refer to
equipment manufacturer's procedures.
Lubricating oil leaks from lubricating oil cooler, head
gasket, head and crankcase.
See Also: Table 8. Coolant - Loss.

18. 21 - Cooling System
00 - General
00 - General
21 - 7 9813/5500-1 21 - 7
Drain and Fill
Consumables
Description Part No. Size
4006/1101 5L
4006/1120 20L
Antifreeze HP/
Coolant ASTM D6210
Concentrate
4006/1103 200L
Visually check the coolant level daily.
Check the quality of the antifreeze mixture and
change it according to the service schedule.
1. Open the engine compartment cover. Refer to
(PIL 06-06).
2. Make sure that the coolant level should be
between the MIN and the MAX marks on coolant
reservoir.
3. If the level in the expansion bottle is low, then
continue with steps 4 to 9.
4. Carefully loosen the cap just enough to let any
pressure escape.
5. Remove the cap when all pressure is released.
6. Fill with pre-mixed water/antifreeze until it
reaches the correct level.
7. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
8. Run the engine for a while to raise the coolant to
working temperature and pressure.
9. Stop the engine and checks for leaks.
Check (Leaks)
Before you start the machine, inspect the system for
leaks:
1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the cooling pack. Refer to (PIL
06-06).
3. Check under the cooling pack and cooling hoses
for signs of leaks.
4. Repair or replace any damaged components
before starting the machine.

19. 21 - Cooling System
00 - General
00 - General
21 - 8 9813/5500-1 21 - 8
Check (Level)
The graphic shows a typical engine cooling system,
the system you are working on may look slightly
different.
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the access cover to get access to the
engine.
3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
cap and top up to the level indicated.
4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
Figure 90.
A
C
B
A Cap
B Bottom radiator hose
C Coolant expansion tank

20. 21 - Cooling System
03 - Cooling Pack
21 - 9 9813/5500-1 21 - 9
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-11

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22. Notes:
21 - 10 9813/5500-1 21 - 10

23. 21 - Cooling System
03 - Cooling Pack
00 - General
21 - 11 9813/5500-1 21 - 11
00 - General
Introduction .................................................... 21-11
Clean ............................................................. 21-12
Introduction
The cooling pack contains the following major
components:
• Radiator
• Cooling fan
• Condenser (air conditioning machines)

24. 21 - Cooling System
03 - Cooling Pack
00 - General
21 - 12 9813/5500-1 21 - 12
Clean
The cooling pack is located in front of the engine,
the pack consists of the engine cooling radiator,
hydraulic oil cooler, intercooler and air-conditioning
condenser (optional). If the cooler tubes/fins get
clogged (by dirt and flies etc.) the radiator and
coolers will be less efficient.
1. Remove the front grille. Refer to (PIL 06-06-21).
2. Brush off all debris from the cooler tubes and fins.
Make sure the loosened material is brushed out
of the cooler enclosure.
2.1. When cleaning the matrix make sure that
the brush follows the same direction as the
fins are to avoid damaging them. Damaged
fins will reduce the cooling efficiency of the
matrix.
3. Install the front grille.
Machines with air conditioning have a condenser
matrix installed in front of the oil cooler, the fins
of the condenser matrix may get clogged. In this
case, clean the tubes/fins of the condenser matrix as
described above.
Figure 91.