Need to tear down the hydrostatic drive on your compact backhoe loader? This 476-page JCB 1CX Service Manual PDF (OEM #9803/9960-4) covers the complete machine, including the Series 1, Series 2, 1CXWS, and 1CXT variants. You get full color-coded hydraulic schematics, complete electrical circuit diagrams, and step-by-step diagnostic procedures for tracking down drive motor faults. Open it up to find page after page of torque tables for zinc-plated and Dacromet fasteners, plus dedicated sections for rebuilding the hydrostatic pump and engine. Install a 0-35 bar pressure gauge in charge pressure gauge port A and verify the system hits a minimum of 7 bar while jogging the starter. Stop wasting hours guessing at test port locations. Grab this bookmarked download, load it on your shop tablet, and get your loader back in the dirt.
Complete the set for your 1CX
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What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Introduction | 6-11 | |
| Torque Settings | 12-19 | Zinc Plated Fasteners and Dacromet Fasteners (Introduction, Bolts and Screws, Hydraulic Connections, 'o' Ring Face Seal System, 'Torque Stop' Hose System) |
| Service Tools | 20-33 | Numerical List Section B - Body and Framework, Tool Detail Reference Section B - Body and Framework, Numerical List Section C - Electrics |
| Service Consumables | 34-35 | Sealing and Retaining Compounds |
| Terms and Definitions | 36-37 | Colour Coding, Hydraulic Schematic Colour Codes |
| Care and Safety | 38-53 | Safety Notices, Safety Check List |
| Maintenance | 54-128 | Service Requirements, Health and Safety, Service Schedules, Fluids, Lubricants and Capacities, Prepare the Machine for Maintenance, Cleaning the Machine, Greasing |
| Attachments | 129-156 | Service Procedures |
| Body and Framework | 157-190 | Service Procedures, Glazing, Excavator, Cab/Canopy Door |
| Electrics | 191-248 | Technical Data, General, Battery, Alternator, Electrical Circuit Diagrams, Harness Data, Control Systems |
| Hydraulics | 249-418 | Technical Data, General, Operation, Schematic Circuits, Fault Finding, Pressure Testing, Pumps, Valves (Series 1 Machines) |
| Transmission | 419-428 | Wheels and Tyres |
| Brakes | 429-434 | Towing and Winching |
| Tracks | 435-466 | Basic System and Operation, Track Damage |
| Engine | 467-476 | Technical Data |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Start-up Procedure for Pumps | Place the machine safely onto blocks, so that all four wheels are clear of the ground. Ensure that the machine is stable. Check that the pump inlet line from the hydraulic filter to the pump unit is filled with fluid, by 'cracking' the hose connection at the rear main pump. Install a 0 - 35 bar (0 - 500 lb/in2, 0 - 35 kgf/cm2) pressure gauge in the charge pressure gauge port A, to monitor the charge pressure. After machine serial no. 751012 a test point is provided which, up to serial no. 751715, is positioned under the pump as shown at B. Remove the ESOS fuse to prevent the engine from starting. With the Drive Control Lever (in the cab) at Neutral, 'jog' the engine using the starter. The pressure gauge should show a small rise in pressure as the engine turns. If so, replace the ESOS fuse and operate the starter whilst slowly increasing the throttle lever setting until the engine starts and runs at the lowest possible speed. As air leaves the system, the charge pressure (as indicated on the gauge) should rise to a minimum of 7 bar (7 kgf/cm2 100 lb/in2). If the charge pressure is incorrect, shut-down and determine the cause. Once the correct charge pressure has been established, operate the drive system 10 times in all directions with the engine at idle then slowly increase the engine speed whilst continuing to operate the system. Finally operate the system in all directions several times with the engine running at maximum speed. Shut down engine and remove the pressure gauge. Check the system fluid level and top up as necessary. | p. 334 |
| Shaft Seal Replacement (Hydrostatic Pump) | Renew O-ring 5 and lip seal 6. Coat outside diameter of new lip seal 6 with suitable sealant. Press lip seal into shaft bearing side of seal carrier 3. Lubricate inside diameter of lip seal 6 with petroleum jelly. Install new O-ring 5 onto seal carrier 3 and lubricate with petroleum jelly. Wrap splined end of shaft 2 with thin plastic to prevent damage to the lip seal during installation. Slide seal carrier 3 over shaft 2 and press into position in the pump body recess. Hold inward pressure against shaft 2, refit circlip 1 to secure the assembly. | p. 336 |
| Shaft Seal Replacement (Drive Motors) | The space between the lips of shaft seal 11 should be filled with JCB HP Grease. | p. 386 |
| General Gasket Replacement | Renew whenever disturbed unless otherwise instructed. | p. 50 |
| JCB Multi-Gasket | Part No. 4102/1212, Quantity 50 ml | p. 34 |
| Auxiliary Pump - Standard Displacement | 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min | p. 255 |
| Auxiliary Pump - Standard Maximum Working Pressure | 185 - 192 bar (2683 - 2785 lbf/in2, 188 - 196 kgf/cm2) | p. 255 |
| Main Relief Valve (M.R.V.) at 1500 rev/min | 207 bar (211 kgf/cm2, 3006 lbf/in2) | p. 256 |
| Pressure Reducing Solenoid Valve Regulated Pressure | 24 Bar (348 lbf/in2, 24.47 kgf/cm2) | p. 256 |
| Extending Dipper Wear Pads Replacement Torque (Item C nuts) | 50 Nm (37 lbf ft) | p. 67 |
| Adjusting the Bottom Wear Pads Clearance (Gap at G) | no greater than 1.5mm (1/16 inch) | p. 68 |
