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
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