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