JCB Robot 260W Service Manual

JCB Robot 260W Service Manual

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

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