(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 Publication No. : 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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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 4x4 Front Axle Pivot Points Backhoe and Stabilisers - Mini CX Backhoe and Stabilisers - Mini CX 4x4 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 4x4 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 4x4 Relays - Mini CX Relays - Mini CX 4x4 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