JCB 1CX, 208S Backhoe Loader Repair Service Manual

1CX (S/N: 751600 to 752999 & S/N: 806000 Onwards) - 208S (S/N: 751600 to 752999 & S/N: 806000 Onwards)
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This service manual PDF download for the 1CX, 208S 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 1CX - S/N: 751600 to 752999
JCB Backhoe Loader 1CX - S/N: 806000 Onwards
JCB Backhoe Loader 208S - S/N: 751600 to 752999
JCB Backhoe Loader 208S - S/N: 806000 Onwards


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 E - Hydraulics
Section F - Transmission
Section G - Brakes
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803-9960-1
Total Pages : 328


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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9803-9960 / 1CX

Section 1
General Information
Introduction
About This Manual
Machine Model and Serial Numbers
Using the Service Manual
Units of Measurement
Section Numbering
Cab/Canopy
Left Side, Right Side
Hydraulic Schematic Colour Codes
Identifying Your Machine
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Typical Product Identification Number (PIN)
Typical Engine Identification Number
Standard 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 Section B - Body and Framework
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
Sealing and Retaining Compounds

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 Decals
Introduction
Safety Decal Recognition

Section 3
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Lifting Regulations - Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid - Oil
Eyes
Swallowing
Skin
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
Calendar Equivalents
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
Additives
Service Requirements for use of B5 Biodiesel
Warranty
Sulphur Content
Effects of Fuel Contaminates
Prepare the Machine for Maintenance
Introduction
How to Make the Machine Safe (Loader Arms Lowered)
How to Make the Machine Safe (Loader Arms Lifted)
Installing the Maintenance Strut
Removing the Maintenance Strut
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
ROPS/FOPS Structure
Checking the ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Every 10 Hours
Quickhitch Pivot Points
Loader Arm Pivot Points
Backhoe Pivot Points
Oiling
Oil the Control Levers
Oil the Door Hinges (Cab machines only)
Slew Oil Level Check
Access Panels
Battery Cover
Removal and Replacement
Engine Cover
Opening and Closing
Engine Side Panels
Removal and Replacement
Floor Plates
Removal and Replacement
Electrical System
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Jump Starting the Engine
Fuses
Relays
Engine
Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Clean the Coolant Radiator
Alternator Drive Belt
Adjusting the Alternator Drive Belt
Air Filter
Cleaning the Air Filter Dust Valve
Changing the Elements
Fuel System
Filling the Tank
Fit the Cap
Drain the Fuel Filter
Changing the Fuel Filter Element
Early Machines
Later Machines
Hydraulic System
Oil and Filter
Checking the Fluid Level
Changing the Filter
Transmission
Drive Chain
Checking the Oil Levels
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Renewing Segments of Optional Non-Inflatable Tyres
Windscreen Washer

Section A
Attachments
General
Quick Release Couplings
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
Maintenance
Shovels
General Purpose and Light Duty Shovels
Daily Maintenance
6-in-1 Shovel
Daily Maintenance
Pallet Forks
Daily Maintenance
Manure/Silage Fork with Top Grab
Daily Maintenance
Attachment Frame
Daily Maintenance

Section B
Body and Framework
General
Slide Hammer Kit
Fitting Procedure
Loader
Loader Arm
Removal
Replacement
Excavator
Dipper
Removal
Replacement
Boom
Removal
Replacement
Kingpost Assembly
Removal and Replacement up to machine no. 807225
Slew Cylinder - Removal
Kingpost - Removal
Kingpost - Replacement
Slew Cylinder - Replacement

Section C
Electrics
Technical Data
Electrical System
Light Bulbs
Sensing Switches
General
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid - Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
100 and 400 series Engines
Dismantling and Assembly
Dismantling
Assembly
Circuit Diagrams
From machine no. 751600 to 752370
Main Components
Fuses
Bulbs
From machine no. 752371 to 752675
Main Components
Fuses
Bulbs
From machine no. 752676
Main Components
Fuses
Bulbs

Section E
Hydraulics
Technical Data
Up to machine number 752462
From machine number 752463
General
Connecting/Disconnecting Hydraulic Hoses
Venting Hydraulic Pressure
Connecting the Hoses
Disconnecting the Hoses
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Operation
General Description up to machine no. 752462
Machine Neutral Circuit
General Description from machine no. 752463
Machine Neutral Circuit
Auxiliary Pump
Loader Valve
Neutral Circuit
Lift Ram Operation 1
Lift Ram Operation 2
Crowd Ram Operation
Shovel Lift (Crowd)
Shovel Open
Relief Valve Operation
Main Relief Valve
View X
View Y.
Auxiliary Relief Valve
Excavator Valve
Neutral Circuit
Operation
Excavator Valve - Bi-Restrictor Operation
Slew Operation
Slew A.R.V. and Anti-Cavitation Operation
A.R.V. Operation
A.R.V. Pressure Relief Operation
1 Valve at Rest
2 Pilot Valve Opens
3 Main Poppet Opens
Pressure Reducing Solenoid Valve
From machine no. 751600
Drive Motor
Transmission in Neutral
Transmission in Forward Drive
Schematic Circuits
Standard Machines - Single Lever Drive Control
From Machine no. 751012 to 752462
From Machine no. 752463
Standard Machines - Dual Lever Drive Control
From Machine no. 751012 to 752462
From Machine no. 752463
High Flow Machines - Single Lever Drive Control
From Machine no. 751012 to 752462
From Machine no. 752463
High Flow Machines - Dual Lever Drive Control
From Machine no. 751012 to 752462
From Machine no. 752463
Optional Hand Tool Circuit
Description
Component Key
Fault Finding
Hydrostatic Transmission
Pumps from machine no. 751012
Machine veers to one side when travelling.
Travel Speed
Checking for Faulty Pump or Motor
Checking Motor Leakage Rate
Checking the Joystick Hydraulic Lines
Loader/Excavator Circuit
Pressure Testing
Main Relief Valve (M.R.V.) - In Situ
Torque Settings
Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump
Torque Settings
Check Valve
Pressure Reducing Valve Cartridge
Charge Pressure Checking and Adjustment
Pumps
Removal and Replacement
Removal
Replacement
Torque Settings
Pump/Engine Coupling
Start-up Procedure
Hydrostatic Pump from machine no. 751012
Dismantling and Assembly
Shaft Seal
Removal and Replacement
Charge Check and High Pressure Relief Valves
Dismantling and Assembly
Charge/Anti-stall Valve
Dismantling and Assembly
Pump Neutral Adjustment
Adjustment procedure
Auxiliary Pump (Standard machines)
Removal and Replacement
Dismantling and Assembly
Dismantling
Inspection
Assembly
Testing
Auxiliary Pump (High-flow machines)
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Valves
Loader Valve
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
Main Relief Valve and Auxiliary Relief Valves
Removal
Dismantling and Assembly
Replacement
Torque Settings
Excavator Valve
Dismantling and Assembly
Check Valves
Spools
Torque Settings
Relief Valves
Hydraclamp Valve
When Dismantling
When Assembling
Torque Settings
Pressure Reducing Solenoid Valve (to serial no. 752462)
Removal
Replacament
Dismantling
Assembly
Brake Valve from serial no. 752463
Dismantling
Assembly
Torque Settings
Drive Motors
Removal and Replacement
Removal of the Drive Sprocket
Removal of Motor
Replacement
Torque Settings
Dismantling and Assembly to machine no. 751011
Dismantling
Assembly
Torque Settings
Dismantling and Assembly from machine no. 751012 to 807172
Dismantling
Assembly
Torque Settings
Later Type Motor with Twin Bearing Output Shaft.
Dismantling
Assembly
Dismantling and Assembly from machine number 807173
Dismantling
Assembly
Torque Settings
Servo Joysticks
All Joysticks
Removal and Replacement
Removal
Replacement
Joystick up to machine number 807146
Dismantling
Assembly
Torque Settings
Handle Replacement
Joystick from machine number 807147
Dismantling
Assembly
Torque Settings
Rams
Typical Ram (with dowelled piston head)
Dismantling and Assembly
Dismantling
Assembly
Torque Settings
Slew Cylinder
Re-seal
Filling Procedure
Filtration
Suction Strainer
Removal and Replacement
Return Filter
Removal and Replacement

Section F
Transmission
Wheels and Tyres
Road Wheels
Removal
Replacement
Wheel Hubs
Removal
Replacement
Dismantling
Assembly
Torque Settings

Section G
Brakes
Towing and Winching
Preparation for Towing/Winching from machine no. 751012
After Towing/Winching

Section K
Engine
Technical Data
100 Series Engine up to machine no. 807552
400 Series Engine from machine no. 807553
Engine Unit
Removal and Replacement
Removal
Replacement
Torque Settings

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