jcb Mini CX - Page 40

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Section 2 - Care & Safety

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Section 0 - Service Manual2
Section 1 - General Information4
Table of Contents5
Introduction7
About this Manual7
Units of Measurement8
Left Side, Right Side8
Cross References8
Identifying Your Machine9
Machine Identification Plate9
Unit Identification10
Section 1 - General Information Introduction11
Torque Settings13
Zinc Plated Fasteners and Dacromet Fasteners13
Hydraulic Connections17
Service Tools21
Numerical List21
Tool Detail Reference Section B - Body and Framework22
Numerical List Section C - Electrics23
Tool Detail Reference Section C - Electrics24
Numerical List Section E- Hydraulics25
Tool Detail Reference Section E- Hydraulics28
Numerical List Section F - Transmission33
Tool Detail Reference Section F - Transmission34
Consumables35
Sealing and Retaining Compounds35
Section 2 - Care & Safety38
Safety Notices41
Safety Warnings41
Safety Checklist42
General Safety42
Operating Safety44
Maintenance Safety47
Safety Decals52
Section 3 - Routine Maintenance58
Service Requirements61
Routine Maintenance Service Requirements62
Obtaining Replacement Parts62
Health and Safety63
Service Schedules67
Fluids, Lubricants and Capacities71
Cleaning the Machine76
Checking for Damage78
Seat Belt79
Checking the ROPS/FOPS Structure80
Loader Arm Safety Strut81
Service Access83
Battery Cover84
Greasing (10 Hours)85
Lubrication89
Electrical System90
Jump Starting the Engine91
Checking the Oil Level93
Changing the Oil and Filter93
Changing the Air Filter Element95
Engine Cooling System96
Checking the Coolant Level96
Changing the Coolant96
Checking the Alternator Belt Tension98
Adjusting the Alternator Belt98
Fuel System99
Types of Fuel99
Filling the Tank100
Draining the Fuel Filter101
Hydraulic System103
Checking the Fluid Level103
Changing the Hydraulic Filter104
Transmission106
Tyres and Wheels107
Tyre Inflation107
Tyre Table108
Section a - Optional Attachments111
Quick Release Couplings113
Connecting and Disconnecting113
Connecting the Hoses115
General Purpose117
Floor Plates123
Removal and Replacement123
Loader Arm125
Removal and Replacement125
Removal and Replacement126
Removal and Replacement127
Kingpost131
Centremount Kingpost131
Sideshift Kingpost132
Service Tools133
Numerical List133
Tool Detail Reference Section B - Body and Framework134
Technical Data139
General Electrical Data139
Light Bulbs139
Test Methods143
Using a Multimeter143
Measuring DC Voltage144
Measuring Resistance144
Measuring Continuity145
Measuring Frequency145
Service Procedures147
Battery147
Maintenance147
Specific Gravity Testing149
Harness Data151
Wire and Harness Number Identification151
Harness Drawings153
Circuit Diagrams159
Early Series 1 Machines159
Later Series 1 Machines161
Series 2 Machines163
Service Tools165
Numerical List165
Tool Detail Reference Section C - Electrics166
Technical Data171
General Data171
Service Procedures175
Hydraulic Contamination175
Cleaning Operation177
Operation Description179
Introduction to Hydraulic Schematic Symbols179
Control Valves183
General Description185
Transmission Pump Operation - Series 1 Machines187
Transmission Pump Operation - Series 2 Machines189
Charge Pump191
Transmission Motor Operation 2WD193
Transmission Operation - Series 1 Machines195
Transmission Operation - 2WD Series 2 Machines198
Transmission Operation - 4WD Series 2 Machines201
Typical Valve Spool Operation207
Main Relief Valve Operation211
Circuit Diagrams213
Series 1 Machines, JCB (+) Pattern Controls213
Series 1 Machines, ISO (+) Pattern Controls215
Series 2 Machines, JCB (+) Pattern Controls - 2WD217
Series 2 Machines, ISO (+) Pattern Controls - 2WD219
Series 2 Machines, JCB (+) Pattern Controls - 4WD221
Series 2 Machines, ISO (+) Pattern Controls - 4WD223
Towing/Winching225
Preparing for Towing/Winching225
Problem Solving229
Hydrostatic Transmission229
Loader/Excavator Circuit240
Pump Assembly Series 1 Machines243
Transmission Pump - Series 1 Machines245
Dismantling and Assembly246
Transmission Pump - Series 2 Machines250
Removal and Replacement250
Service Pump259
Drive Motors269
Axle Drive Motor269
Dismantling and Assembly270
Wheel Drive Motors274
Loader Valve301
Excavator Valve303
Removal and Replacement303
Dismantling and Assembly305
Typical Spool307
Stabiliser Spool308
Excavator Auxiliary Valve309
Pressure Testing310
Typical Ram315
Slew Ram321
Oil Cooler325
Service Tools327
Section F - Transmission337
Wheel Removal and Replacement339
Front Axle341
Removal and Replacement341
Front Axle342
Removal and Replacement342
Dismantling and Assembly347
Service Tools349
Numerical List349
Tool Detail Reference Section350
Section G - Brakes353
Parking Brake355
Removal and Replacement355
Dismantling and Assembly356
Testing the Parking Brake357
Adjusting the Parking Brake358
Section H - Steering360
Section H362
Hydraulic Steering Unit363
Description363
Removal and Replacement364
Dismantling and Assembly366
Power Track Rod369
Removal and Replacement369
Dismantling and Assembly371
Technical Data377

jcb Mini CX - Page 40

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