JCB Robot 260W Service Manual PDF Download

JCB Robot 260W Service Manual

PDF Format
450 pgs.

Contents Page No.

Introduction

About this Publication ................................................................................ 1-1

Machine Model and Serial Number .......................................................1-1

Using the Service Manual .....................................................................1-1

Section Numbering ................................................................................1-1

Left Side, Right Side ..............................................................................1-2

Cab/Canopy ..........................................................................................1-2

Machine Description .................................................................................. 1-3

The JCB Skid Steer Loader ...................................................................1-3

Intended Use .........................................................................................1-3

Component Locations ...........................................................................1-3

Identifying Your Machine ........................................................................... 1-5

Machine Identification Plate ..................................................................1-5

Component Identification .......................................................................1-6

ROPS and FOPS ..................................................................................1-7

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-9

Introduction ............................................................................................1-9

Bolts and Screws ...................................................................................1-9

Hydraulic Connections ............................................................................. 1-13

O Ring Face Seal System ..................................................................1-13

Service Tools

Numerical List .......................................................................................... 1-15

Tool Detail Reference .............................................................................. 1-17

Section B - Frame and Bodywork ........................................................1-17

Section C - Electrics ............................................................................1-21

Section E - Hydraulics .........................................................................1-22

Section K - Engine ...............................................................................1-26

Service Aids

Sealing and Retaining Compounds ......................................................... 1-27

Contents Page No.

Safety Notices

Important Information ................................................................................ 2-1

The Operator Manual ............................................................................2-1

Safety Warnings ....................................................................................2-1

Safety Check List ....................................................................................... 2-2

Safety - Yours and Others .....................................................................2-2

General Safety ......................................................................................2-2

Operating Safety ...................................................................................2-4

Maintenance Safety ...............................................................................2-8

Contents Page No.

Routine Maintenance

Service Requirements ............................................................................... 3-1

Introduction ............................................................................................3-1

Owner/Operator Support .......................................................................3-1

Service/Maintenance Agreements ........................................................3-1

Fit for Purpose Tests for Lifting Equipment ............................................3-2

Obtaining Replacement Parts ................................................................3-2

Health and Safety ...................................................................................... 3-3

Lubricants ..............................................................................................3-3

Battery ...................................................................................................3-5

Service Schedules ..................................................................................... 3-7

Introduction ............................................................................................3-7

How to Use the Service Schedules .......................................................3-7

Calendar Equivalents ............................................................................3-7

Service Label .........................................................................................3-8

Pre-start Cold Checks, Service Points and Fluid Levels ..................... 3-11

Fluids, Lubricants and Capacities ............................................................ 3-15

Coolant Mixtures .................................................................................3-16

Fuels ....................................................................................................3-17

Tools ........................................................................................................ 3-20

Carrying Tools onto the Machine .........................................................3-20

Tool Locations (optional) .....................................................................3-20

Prepare the Machine for Maintenance .................................................... 3-21

Introduction ..........................................................................................3-21

How to Prepare the Machine for Maintenance (Loader Arm Lowered) ......

3-23

How to Prepare the Machine for Maintenance (Loader Arm Lifted) ....3-23

How to Prepare the Machine for Maintenance (Loader Arm and Cab Lifted)

3-26

Cleaning the Machine .............................................................................. 3-27

Introduction ..........................................................................................3-27

Preparing the Machine for Cleaning ....................................................3-27

Cleaning the Machine ..........................................................................3-27

Checking for Damage .............................................................................. 3-30

Check the Machine Body and Structure ..............................................3-30

Check the Tyres ..................................................................................3-30

Check the Seat and Seat Belt .............................................................3-30

Check the Hydraulic Hoses and Fittings .............................................3-31

Checking the ROPS/FOPS Structure ..................................................3-31

Greasing .................................................................................................. 3-32

Introduction ..........................................................................................3-32

Preparing the Machine for Greasing ...................................................3-32

Every 50 Hours ....................................................................................3-33

Access Panels ......................................................................................... 3-35

Introduction ..........................................................................................3-35

Rear Door ............................................................................................3-35

Engine Top Cover ................................................................................3-36

Cab ......................................................................................................3-37

Heater and Air Conditioning (option) ....................................................... 3-40

Changing the Intake Filter ...................................................................3-40

Changing the Re-circulation Filter .......................................................3-40

3-i 3-i

Section 3 - Maintenance

Contents

Contents Page No.

Electrical System ..................................................................................... 3-41

Battery .................................................................................................3-41

Jump Starting the Engine ....................................................................3-43

Fuses and Relays ................................................................................3-44

Battery Isolator (Option) ......................................................................3-48

Engine ..................................................................................................... 3-49

Oil and Filters ......................................................................................3-49

Cooling system ....................................................................................3-52

Alternator Belt ......................................................................................3-54

Engine Air Filter ...................................................................................3-57

Fuel System ............................................................................................. 3-59

Introduction ..........................................................................................3-59

Draining the Primary Water Separator and Engine Fuel Filter ............3-60

Changing the Primary Water Separator Filter .....................................3-61

Fuel Filter ............................................................................................3-62

Hydraulic System ..................................................................................... 3-64

Introduction ..........................................................................................3-64

Releasing the Auxiliary Hydraulic Pressure ........................................3-65

Oil and Filters ......................................................................................3-66

Hydraulic Tank Breather ......................................................................3-68

Transmission ........................................................................................... 3-69

Drive Chain Lubrication - Wheeled Machines .....................................3-69

Drain Line Screen Filter Adapter .........................................................3-70

Tyres and Wheels .................................................................................... 3-71

Tyre Inflation ........................................................................................3-71

Checking the Wheel Nut Torques ........................................................3-72

Tracks ...................................................................................................... 3-73

Track Adjustment .................................................................................3-73

Front Screen Washer (optional) .............................................................. 3-74

Checking the Level ..............................................................................3-74

Fire Extinguisher (if fitted) ........................................................................ 3-75

Checking the Fire Extinguisher ...........................................................3-75