JCB Midi CX Backhoe Loader Backhoe Loader Repair Service Manual

(S/N: 972021 to 985136 - S/N: 1327001 to 1349999)
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This service manual PDF download for the Midi CX JCB Backhoe Loader 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 Midi CX
S/N: 972021 to 985136
S/N: 1327001 to 1349999


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
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. : 9803/9400-08
Total Pages : 623


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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9803-9400

Section 1
General Information
Introduction
About this Publication
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cab/Canopy
Cross References
Identifying the Machine
Machine Identification Plate
Component Identification Plates
Fuel
Types of Fuel
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
'Torque Stop' Hose System
Service Tools
Numerical List
Service Aids
Sealing and Retaining Compounds
Terms and Definitions
Colour Coding
Hydraulic Schematic Colour Codes

Section 2
Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification

Section 3
Maintenance
Routine Maintenance
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Loader Arm Lowered)
How to Make the Machine Safe (Loader Arms Lifted)
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
ROPS/FOPS Structure
Checking The ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Loader Arms
Backhoe
Front Axle
Multi Purpose Shovel
Stabilisers
Kingpost
Sideshift Cross Rails
Access Panels
Engine Cover
Heater and Air Conditioning
Cleaning the Cab Heater Filter
Brakes
Park Brake Adjustment
Checking the Foot Brake Fluid Level
Electrical System
Battery
Jump Starting The Engine
Fuses
Link Box Fuses
Relay Identification
Engine
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant
Changing the Coolant
Alternator Drive Belt
Changing the Air Filter Elements
Fuel System
Fuel
Filling the Tank
Draining the Fuel Filter
Changing the Engine Fuel Filter Element
Priming the System
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
Checking the Fluid Level
Hydraulic Tank Cap
Changing the Filter Element
Changing the Suction Strainer
Transmission Charge Pump Filter
Cleaning the Hydraulic Cooler
Axles
Rear Axle
Front Axle
Tyres and Wheels
Tyre Inflation
Wheel Nuts
Wear Pads
Stabiliser Legs (Sideshift Machines Only)
Windscreen Washer
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A
Attachments
Service Procedures
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings

Section B
Body and Framework
Service Tools
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Cab Air Conditioning SYSTEM
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
System Operation
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Fault Indications
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Refrigerant Charge Level
Binary Pressure Switch
Refrigerant
Refrigerant Charging and Discharging
Cleaning the Cab Filter
Compressor Drive Belt - Adjustment
Cab
Introduction
ROPS, FOPS Structure - Checks
Removal and Replacement
Direct Glazing
Cab Mountings
Side Console
Front Steer Console
Air Conditioning Condenser
Introduction
Cleaning
Cab HVAC Unit
Introduction
Removal and Replacement
Air Conditioning Unit (HVAC)
Blower Unit
Cab Seat
Introduction
Removal and Replacement
Fuel Tank
Introduction
Removal and Replacement
Fuel Level Sender
Hydraulic Tank
Introduction
Removal and Replacement
Fluid Level Sight Glass
Filter Cover Plate
Engine Cover
Introduction
Removal and Replacement
Grille Housing
Introduction
Removal and Replacement
Loader Arms
Introduction
Removal and Replacement
Stabiliser Legs
Introduction
Sideshift
Wear Pads
Wear Pad - Adjustment
Removal and Replacement
Centremount
Sideshift
Stabiliser Leg Alarm SYSTEM
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Leg Alarm Switch - Adjustment
Boom and Dipper
Introduction
Removal and Replacement
Boom
Dipper
Kingpost
Introduction
Removal and Replacement
Sideshift Carriage
Introduction
Removal and Replacement

Section C
Electrics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
General Electrical Data
Fuses and Relays
Fuses
Link Box Fuses
Relays
Relays
Schematic Circuits
Backhoe Loader
Primary Fuses, Ignition Switch, Ignition Relays and Starter Motor
Instrumentation
Fuel Lift Pump, Interior Light, Radio and Face Fan
Front Wiper, Rear Wiper, Heater/Air Conditioning and SRS
Front and Rear Worklights, Beacon and Horn
Roadlights
Forward/Reverse, High-Low Speed, Inching, PTO and Stabiliser Leg Alarm
Earthing Points
Rearframe Joysticks Enable and Hydraclamps (Sideshift)
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Harness Data
Drawings and Interconnection
Harnesses
Drawings

Section D
Controls
Service Tools
Numerical List
Steering Column
Removal and Replacement
Column Switches
Removal and Replacement
Control Rods and Linkages
Dismantle and Assemble
Loader Valve Controls
Excavator Valve Controls (Centremount)
Stabiliser Controls (Sideshift)
Control Cables
Removal and Replacement
Boom Lock Cable
Anti-Spill Mechanism
Operation and Adjustment

Section E
Hydraulics
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Hydraulic Services Pump
Hydraulic Services Cycle Times
Loader Valve (3 Spool)
Loader Valve (4 Spool)
Excavator Valve (Centremount)
Excavator Valve (Sideshift)
Hydraulic Rams
3 Point Hitch - if fitted
Hitch Lift Unit
PTO Hydraulic Motor
Smooth Ride System (SRS) - if fitted
Accumulator
Systems Operation
General Description
Hydraulic Services System
Excavator Servo Controls (Sideshift)
3 Point Hitch - if fitted
Hydraulic Services Pump
Flow and Pressure Regulator Valves
Loader and Excavator Valve Services
Pressure Compensator Valves
No Service Selected (System Standby Pressure)
Operating a Service
Operating an Individual Service
Operating Multiple Services
Excavator Servo Controls (Sideshift)
Joystick Controllers
Combined Servo Pressure Generating Valve & Hydraclamps Valve
ISO and SAE Control Pattern Changeover Valve
Loader Self Level Circuit
Self Level Valve
Loader Arms Raise
Loader Arms Raise - Shovel Rams Fully Extended
Loader Arms Lower
Smooth Ride System (SRS) - if fitted
Electrical Description
Wires and Connectors
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
Backhoe Loader - Centremount
Backhoe Loader - Sideshift
3 Point Hitch and PTO Option
Fault Finding
Hydraulic Services System
Fault Finding Tables
3 Point Hitch - if fitted
Fault Finding Tables
Loader Self Level Circuit
Smooth Ride System (SRS) - if fitted
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Connecting and Disconnecting Hydraulic Hoses
Venting Hydraulic Pressure
Connecting the Hoses
Disconnecting the Hoses
Flow and Pressure Tests
Checking Pump Flow
Testing the Main System Pressure
Testing Auxiliary Relief Valves (ARV's)
Testing the Standby Pressure
Pressure Compensator Network - Testing
Testing the Servo Pressure (Sideshift)
3 Point Hitch - if fitted
Hitch Lift Unit Cycle Test
Hitch Lift Unit Leakage Tests
Position Feedback Linkage - Adjustment
Smooth Ride System (SRS) - if fitted
Accumulator Charging and Discharging
Hydraulic Services Pump
Removal and Replacement
Dismantle and Assemble
Loader Valve
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Priority Inlet Spool
Standard Spool
Mechanical Detent Spool
Electric Detent Spool
Solenoid Operated Spool
Load Sense Relief Valve (LSRV)
Flow Regulator Valve
Internal Auxiliary Relief Valves (ARV's)
Pressure Compensator Valves
Load Hold Check Valves
Excavator Valve
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Manually Operated Spool
Servo Operated Spool
Auxiliary Relief Valves (ARV's)
Pressure Compensator Valves
Load Hold Check Valves
Joystick Controllers (Sideshift)
Removal and Replacement
Dismantle and Assemble
3 Point Hitch - if fitted
Removal and Replacement
Hitch Lift Unit
PTO Hydraulic Motor
Dismantle and Assemble
Hitch Lift Unit
PTO Hydraulic Motor
Hose Burst Protection Valves
Hydraulic Operation and Schematics - Stabiliser HBPV
Twin Check Valves
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Loader Shovel Ram
Loader Lift Ram
Stabiliser Ram (Centremount)
Stabiliser Ram (Sideshift)
Excavator Bucket Crowd Ram
Excavator Dipper Ram
Excavator Boom Ram
Slew Ram
Dismantle and Assemble
Typical Ram
Slew Ram
JCB Ram Sealing Procedure
Oil Cooler Matrix
Removal and Replacement
Smooth Ride System (SRS) - if fitted
Accumulator
Removal and Replacement

Section F
Transmission
Service Tools
Numerical List
Tool Detail Reference
Technical Data
Tyre Sizes and Pressures
Front Axle
Unit Identification
Specifications
Rear Axle
Unit Identification
Specifications
Hydrostatic Transmission
Transmission Pump
Transmission Motor
Creep Valve - if fitted
Moving a Disabled Machine
Preparation for Towing/Winching
Systems Operation
General Description
Hydrostatic Transmission
Creep Speed Control - if fitted
Transmission Pump
Pump Control Circuit
Transmission Motor
Motor Control Circuit
Forward/Reverse Drive Control
Electrical Description
Wires and Connectors
High/Low Speed Range
Electrical Description
Wires and Connectors
Schematic Circuit
Midi CX Backhoe Loader
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Hydrostatic Transmission
Priming Procedure
Flow and Pressure Tests
Rear Axle
Testing for Brake Piston Seal Leakage
Fault Finding
Hydrostatic Transmission
Fault Finding Tables
Pump and Motor Hydraulic Test Ports
Transmission Pump
Removal and Replacement
Pump Drive Coupling
Dismantle and Assemble
Transmission Motor
Removal and Replacement
Dismantle and Assemble
Propshaft
Removal and Replacement
Front Axle SD40
Removal and Replacement
Dismantle and Assemble
Rear Axle PD40
Removal and Replacement
Dismantle and Assemble
Transfer Gearbox (Drop-box)
Dismantle and Assemble
Oil Cooler Matrix
Removal and Replacement

Section G
Brakes
Service Tools
Numerical List
Technical Data
Service Brakes
Park Brake
Systems Operation
General Description
Compensating Master Cylinder
Pedals Locked - Normal Operation
Pedals Locked - Compensating Operation
Pedals Unlocked - Normal Operation
Inching Control
Inching Valve
Electrical Description
Wires and Connectors
Fault Finding
Brake System
Fault Finding Tables
Service Procedures
Service Brakes
Bleeding the System
Brake Light Switch - Adjustment
Brake Piston Seal Leakage Test
Park Brake
Testing the Park Brake
Brake Cable Adjustment
Switch Adjustment
Compensating Master Cylinder
Removal and Replacement
Dismantle and Assemble
Service Brakes
Dismantle and Assemble
Park Brake
Dismantle and Assemble

Section H
Steering
Service Tools
Numerical List
Technical Data
Hydraulic Steer Unit
Priority Valve
Systems Operation
General Description
Steer Circuit Schematic
Priority Valve
Neutral
Turning
Hydraulic Steer Unit
Neutral
Left Turn
Right Turn
Right turn, Unassisted
Shock Valve
Fault Finding
Steering System
Fault Finding Tables
Service Procedures
Bleeding the System
Testing the System Pressure
Priority Valve
Removal and Replacement
Power Track Rod
Removal and Replacement
Link Arms
Removal and Replacement
Ram
Dismantle and Assemble
Hydraulic Steer Unit
Removal and Replacement
Dismantle and Assemble

Section K
Engine
Technical Data
400 Series
Unit Identification
Engine Specifications
Engine Cooling Pack
Removal and Replacement
Dismantle and Assemble
Removal and Replacement
400 Series
Component Identification

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