JCB Backhoe Loader Mini CX Repair Service Manual

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(S/N: 930000 Onwards)

This service manual PDF download for the JCB Mini CX has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Backhoe Loader Mini CX
S/N: 930000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care & Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body & Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9340-8
Total Pages : 378

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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More Info : http://www.sitelux.com

9803-9340 / Mini CX

Section 1
General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cross References
Location of Handbook
Identifying your Machine
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Unit Identification
Tier 3 Typical Engine Identification Number
ROPS and FOPS
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference Section B – Body and Framework
Numerical List Section C – Electrics
Tool Detail Reference Section C – Electrics
Numerical List Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
Numerical List Section F – Transmission
Tool Detail Reference Section F – Transmission
Consumables
Sealing and Retaining Compounds

Section 2
Care & Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Checklist
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Introduction
Safety Decal Recognition

Section 3
Routine Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Initial Service and Inspection (250 Hours)
Lifting Regulations – Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
First Aid – Oil
Spillage
Fires
Battery
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
Introduction
How to Use the Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels
Acceptable and Unacceptable Fuels
Sulphur Content
Effects of Fuel Contaminates
Cleaning the Machine
Introduction
Detergents
Pressure Washing and Steam Cleaning
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
Checking the ROPS/FOPS Structure
Loader Arm Safety Strut
Installing the Safety Strut
Removing the Safety Strut
Service Access
Opening and Closing the Engine Cover
Removing the Front Floor Plate
Battery Cover
Greasing (10 Hours)
Introduction
Loader Arm Pivot Points – Mini CX
Loader Arm Pivot Points – Mini CX 4×4
Front Axle Pivot Points
Backhoe and Stabilisers – Mini CX
Backhoe and Stabilisers – Mini CX 4×4
Lubrication
Oiling Control Levers
Electrical System
Battery
Battery Disconnection/Connection
Checking the Electrolyte Level
Jump Starting the Engine
Engine
Checking the Oil Level
Changing the Oil and Filter
Changing the Air Filter Element
Engine Cooling System
Checking the Coolant Level
Changing the Coolant
Cleaning the Coolant Radiator
Checking the Alternator Belt Tension
Adjusting the Alternator Belt
Fuel System
Types of Fuel
Recommended Fuel Specification
Acceptable Fuel Specification
Sulphur Content
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Petrol
Filling the Tank
Draining the Fuel Filter
Changing the Fuel Filter Element
Hydraulic System
Checking the Fluid Level
Changing the Hydraulic Filter
Checking the Slew Gearbox Oil Level – Mini CX 4×4
Transmission
Checking the Rear Axle Oil Level – Mini CX
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torque
Tyre Table

Section A
Attachments
Hoses and Couplings
Quick Release Couplings
Connecting and Disconnecting
Quick Release Couplings – Do’s and Don’ts
Connecting Quick Release Couplings
Disconnecting Quick Release Couplings
Connecting/Disconnecting Hydraulic Hoses
Venting Hydraulic Pressure
Connecting the Hoses
Disconnecting the Hoses
Shovels
Maintenance
General Purpose
Daily Maintenance
4-in-1 Shovel
Daily Maintenance

Section B
Body & Framework
Floor Plates
Removal and Replacement
Front Floor Plate – Series 1 Machines
Removal and Replacement
Front Floor Plate – Series 2 Machines
Removal and Replacement
Rear Floor Plate
Removal and Replacement (not illustrated)
Loader Arm
Removal and Replacement
Removal
Replacement
Dipper
Removal and Replacement
Removal
Replacement
Boom
Removal and Replacement
Removal
Replacement
Kingpost
Centremount Kingpost
Removal
Replacement
Sideshift Kingpost
Removal
Replacement
Service Tools
Numerical List
Tool Detail Reference Section B – Body and Framework

Section C
Electrics
Technical Data
General Electrical Data
Light Bulbs
Fuses – Mini CX
Fuses – Mini CX 4×4
Relays – Mini CX
Relays – Mini CX 4×4
Test Methods
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Service Procedures
Battery
Maintenance
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Drawings
Harnesses
Circuit Diagrams
Early Series 1 machines
Main Components
Lamps
Fuses
Later Series 1 machines
Main Components
Lamps
Fuses
Series 2 machines
Main Components
Lamps
Fuses
Service Tools
Numerical List
Tool Detail Reference Section C – Electrics

Section E
Hydraulics
Technical Data
General Data
Loader Pump – Series 1 Machines
Loader Pump – Series 2 Machines
Transmission Pump – Series 1 Machines
Transmission Pump – Series 2 Machines, 2WD
Transmission Pump – Series 2 Machines, 4WD
Hydraulic Motor – 2WD (Axle mounted)
Front Wheel Hydraulic Motor – 4WD
Rear Wheel Hydraulic Motor – 4WD
Relief Valve Operating Pressures
Filter
Rams
Dimensions
Torque Settings
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Cleaning Operation
Procedure
Operation Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
General Description
Machine Neutral Circuit
Transmission Pump Operation – Series 1 Machines
Charge Pressure Valve
High Pressure Relief Valves
By-pass (Tow) Valve
Transmission Pump Operation – Series 2 Machines
Axial Piston Pump
Charge Pump
Displacement Angle (DA) Control Valve
Swash Control Piston
Directional Control Valve (DCA)
High Pressure relief Valve and Control Pressure Make-up Valve (HPRV)
Transmission Motor Operation 2WD
Loop Flushing System
Transmission Operation – Series 1 Machines
Neutral
Forward
Reverse
Transmission Operation – 2WD Series 2 Machines
Neutral
Forward
Reverse
Transmission Operation – 4WD Series 2 Machines
Neutral
Forward
Reverse
Typical Valve Spool Operation
Neutral Circuit
Spool Open Selected – 1
Spool Open Selected – 2
Spool Closed Selected
Main Relief Valve Operation
Circuit Diagrams
Series 1 Machines, JCB (+) pattern controls
Component Key
Series 1 Machines, ISO (+) pattern controls
Component Key
Series 2 Machines, JCB (+) pattern controls – 2WD
Component Key
Series 2 Machines, ISO (+) pattern controls – 2WD
Component Key
Series 2 Machines, JCB (+) pattern controls – 4WD
Component Key
Series 2 Machines, ISO (+) pattern controls – 4WD
Component Key
Towing/Winching
Preparing for Towing/Winching
Series 1 Machines
Before Towing/Winching
After Towing/Winching
Series 2 Machines
Before Towing/Winching
After Towing/Winching
Series 2 Machines with Wheel Mounted Hydraulic Motors
After Towing/Winching
Problem Solving
Hydrostatic Transmission
Hydrostatic Transmission Circuit – Series 1 Machines
Transmission Pump Neutral Adjustment – Series 1 Machines
Adjustment
Checking Motor Speed – Series 1 Machines
Checking Motor Leakage Rate (2WD)
Pump Pressure Test Points – Series 1 Machines
Pump Pressure Test Points – Series 2 Machines
Testing High Pressure Relief Valves
Series 1 Machines
Series 2 Machines
Alternative Method
Series 1 Machines
Series 2 Machines
Loader/Excavator Circuit
Pumps
Pump Assembly Series 1 Machines
Removal
Replacement
Transmission Pump – Series 1 Machines
Dismantling and Assembly
Dismantling
Transmission Pump – Series 2 Machines
Removal and Replacement
Removal
Transmission Pump – Series 2 Machines
Drive Shaft Oil Seal
Charge Pump Oil Seal
Control Piston Cover Seals
High Pressure Relief Valve
Low Pressure Relief Valve
Pressure Cut-off Valve
Control Unit
Service Pump
Removal and Replacement
Removal
Replacement
Dismantling and Assembly – Series 1 Machines
Dismantling
Inspection
Assembly
Service Pump – Series 2 Machines
Dismantling
Inspection
Assembly
Pump/Engine Coupling
Start-up Procedure – Series 1 Machines
Start-up Procedure – Series 2 Machines
Drive Motors
Axle Drive Motor
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
Dismantling
Wheel Drive Motors
Wheel Drive Motor – Front (4 Wheel drive)
Removal
Replacement
Torque Settings
Wheel Drive Motor – Rear
Removal
Replacement
Torque Settings
Wheel Drive Motor – Brake
Dismantling
Assembly
Wheel Drive Motor – Bearing Support
Dismantling
Assembly
Wheel Drive Motor – Roller Block
Dismantling
Assembly
Wheel Drive Motor – Valve
Dismantling
Assembly
Wheel Drive Motor – End Cover Seal
Dismantling
Assembly
Valves
Loader Valve
Removal
Replacement
Torque Settings
Dismantling and Assembly
Torque Settings
Excavator Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Torque Settings
Typical Spool
Dismantling and Assembly
Spools
Check Valves
Auxiliary Relief Valves
Stabiliser Spool
Dismantling and Assembly
Spools
Check Valves
Excavator Auxiliary Valve
Removal and Replacement
Removal
Replacement
Torque Settings
Dismantling and Assembly
Pressure Testing
Main Relief Valve (MRV) – In situ
Auxiliary Relief Valve (ARV) – Using Hand Pump
Torque Settings
Steering Priority Valve
Removal
Replacement
Torque Settings
Loader Change-over Valve
Removal
Replacement
Rams
Typical Ram
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembling
New rod and piston head
New piston head fitted to a pre-drilled piston rod
New piston rod fitted to a pre-drilled piston head
JCB Ram Sealing Procedure
Slew Ram
Removal
Replacement
Dismantling and Assembly
Dismantling
Oil Cooler
Oil Cooler Connections
Removal and Replacement
Service Tools
Numerical List
Tool Detail Reference Section E- Hydraulics

Section F
Transmission
Wheels
Wheel Removal and Replacement
Removal
Replacement
Front Axle
Removal and Replacement
Removal
Replacement
Front Axle
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Hub Dismantling
Hub Assembly
Steering Swivel Dismantling
Steering Swivel Assembly
Service Tools
Numerical List
Tool Detail Reference Section

Section G
Brakes
Parking Brake
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Testing the Parking Brake
Adjusting the Parking Brake

Section H
Steering
Hydraulic Steering Unit
Description
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembling
Pressure Relief Valve Cartridge
Power Track Rod
Removal and Replacement
Removal
Replacement
Torque settings
Dismantling and Assembly
Dismantling
Assembling

Section K
Engine
Technical Data
Technical Data up to machine no. 1042315
General Data
Speeds
Fuel System
Cooling System
Technical Data from machine no. 1042316
General Data
Speeds
Fuel System
Cooling System

 

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JCB Backhoe Loader Mini CX Repair Service Manual.pdf

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