Jcb 2 0dg, 2 5dg, 3 0dg, teletruk service repair manual sn（78001 onwards） by kjsmfmmf

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General Information Care & Safety Routine Maintenance Attachments

Service Manual

Body & Framework Electrics Controls

Teletruk From M/c No. 788001

Hydraulics Transmission Brakes

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB AFTERMARKET TRAINING; © WOODSEAT, ROCESTER, STAFFORDSHIRE, ST14 5BW, ENGLAND Tel. ROCESTER (01889) 594700 PRINTED IN ENGLAND Publication No. 9803/3400 Issue 16 Copyright © 2006 JCB AFTERMARKET TRAINING All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Steering Engine

1 2 3 A B C D E F G H K

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Introduction

General This Service Manual is designed for the benefit of JCB Distributor Service Engineers who are receiving or have received, training by JCB Technical Training Department. These personnel have a sound knowledge of safe workshop practices, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The replacement of oil seals, gaskets and any other components showing obvious signs of wear or damage is expected as a matter of course. Components should be cleaned and lubricated where appropriate, and any open hose or pipe connection must be blanked off to prevent the loss of hydraulic fluid or allow an ingress of dirt. Finally, please remember SAFETY COMES FIRST!

Service Manual Layout This Service manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

General Information Care and Safety Routine maintenance

The remaining sections are alphabetically coded and deal with the overhaul and inspection of specific components, for example: A B

Attachments Body and Framework ....etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new information in later issues of this Service Manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted, where necessary, at the beginning of each alphabetically coded section. Read the section contents to locate machine types, machine type identification is not listed on individual pages. All sections are listed on the front cover; tabbed divider cards align directly with each individual section for quick reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads. Torque figures for lubricated threads can be reduced by one third. “Left Hand” and “Right Hand” are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machine type: Teletruk Product Identification Number (PIN) 0788001

9803/3400

Issue 1

Section 1

General Information

Section 1

Contents Identification - Vehicle Identification Number - Unit Identification * - Typical Engine Identification Number

Page No.

1-1 1-1 1-1

Torque Settings * - Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1 * - Metric Grade 8.8 Bolts 2-1 UNF Grade “S” Bolts 2 -1 * 2-2 * - Hydraulic Fittings & Torque Settings 2-2 * - ‘O’ Ring Face Seal System Torque Stop Hose System 2 -3 * Service -

Tools Numerical List Body and Framework Electrics Hydaulics

Sealing and Retaining Compounds

9803/3400

3 3 3 3

1 2 5 6

4-1

Issue 4*

Section 1

General Information

Section 1

Identification

1-1

Vehicle Identification Number (VIN)

1-1

The Product Identification Number (PIN), transmission pump serial number and engine serial number positively identify the type of Teletruk that you have. These numbers are stamped on the machine VIN plate as shown in the following Figure. A typical VIN is a 17 digit number as follows: 401571

SLP TLT25 V E 0788001 SLP TLT25 V E 0788001

Manufacturer (JCB) Machine Model (Teletruk) Year (1997) Country (England) (PIN)

J.C.BAMFORD EXCAVATORS LTD. ROCESTER, STAFFS, ENGLAND.

CONSTRUCTOR

Vehicle Identification No.

Unit Identification To confirm the identity of your machine, check the VIN plate details against the serial numbers of each component.

MADE IN UK

Product Identification No.

ENGINE SERIAL No.

WEIGHT

PUMP SERIAL No.

YEAR OF MANUFACTURE

MODEL

80/1269/EEC POWER KW R.P.M.

MODEL

80/1269/EEC POWER KW R.P.M.

Typical Engine Identification Number This applies to the diesel engines only. HR A

51245 B

817/16599

U C

A Engine Type KR = 4 cylinder naturally aspirated - up to machine serial number 892816. HP = 4 cylinder naturally aspirated - low emission stage 2 from machine serial number 892817. HR = 4 cylinder turbo - low emission stage 2 - 3.5 machines only. Where the service procedure differ between the engine types, the text and or the illustration will specify. B Build Number C Country of Origin

9803/3400

Issue 3*

Section 1

General Information Torque Settings

2-1 *

Section 1 2-1

Introduction - Zinc Plated Fasteners and Dacromet Fasteners JCB Teletruks are assembled using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow plating used on earlier machines. The two types of fasteners can be readily identified by colour and part number suffix as follows: Fastener Type Zinc and Yellow Dacromet

Colour Golden finish Mottled silver finish

Part Number ‘Z’ (e.g. 1315/3712Z) ‘D’ (e.g. 1315/3712D)

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fasteners. Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt. Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. Metric Grade 8.8 Bolts Bolt size Diameter mm

Hexagon (A/F) mm

M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5

10 13 17 19 22 24 27 30 36 46

Zinc Plated Fasteners Torque Settings Nm kgf m lbf ft

Dacromet Fasteners Torque Settings Nm kgf m lbf ft

12 28 56 98

1.2 3.0 5.7 10

9 21 42 72

244 350 476 822 1633

25 36 48 84 166

180 258 352 607 1205

9 22.5 47.5 80 133 200 278 392 675 1348

0.9 2.3 4.8 8.2 13.6 20.4 28.4 40 69 138

7 17 35 59 98 148 205 289 498 994

UNF Grade 'S' Bolts Bolt Size in 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16

11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/3400

Issue 2*

Section 1

General Information

2-2

Section 1

Hydraulic Fittings & Torque Settings

2-2

‘O’ Ring Face Seal System Adaptors screwed into valve blocks Adaptors screwed into valve blocks, etc. seal onto an 'O' ring which is compressed into a 45o seat machined in the face of the tapped port.

Adaptor Size 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

19 22 27 30 32 38

18 31 49 60 81 129 206

0.75 0.875 1 1.25 1.5

13 23 36 44 60 95 152

SAE Tube Size

SAE Port Thread Size

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

4 6 8 10 12 16 20

7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1.1/16 - 12 1.5/16 - 12 1.5/8 - 12

15.9 19.1 22.2 27.0 31.8 38.1 47.6

20 - 28 46 - 54 95 - 105 130 - 140 190 - 210 290 - 310 280 - 380

0.625 0.750 0.875 1.063 1.250 1.500 1.875

16.5 - 18.5 34 - 40 69 - 77 96 - 104 141 - 155 216 - 230 210 - 280

Hoses Screwed onto Adaptors Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45o seat machined in the face of the adaptor port. Dimension will vary depending on torque applied.

C B A

Hose Size 1/8” BSP 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP 1 1/2” BSP 9803/3400

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

14 19 22 27 30 32 38

14 24 33 44 58 84 115 189 244

0.75 0.875 1 1.25 1.5

A438690

10 18 24 33 43 62 85 140 180 Issue 1

Section 1 2-3

General Information

Section 1

Hydraulic Fittings & Torque Settings

2-3

Torque Stop Hose System 'Torque Stop' Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45o seat machined in the face of the adaptor port. To prevent the ‘O’ ring being damaged as a result of over tightening, 'Torque Stop' Hoses have an additional shoulder, which acts as a physical stop. Minimum dimension fixed by shoulder D.

B D A

Hose Size 1/8” BSP 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP 1 1/2” BSP

9803/3400

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

14 19 22 27 30 32 38

14 27 40 55 65 95 120 189 244

0.75 0.875 1 1.25 1.5

A438700

10 20 30 40 48 70 89 140 180

Issue 1

Section 1

General Information Service Tools

3-1

Numerical List 1406/0011 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1612/0006 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/1201 4104/0251 4104/0253 4104/1310 * 331/27987 * 721/11069 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/50043 816/55038 816/55040 816/60096 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105 892/00047 892/00048 892/00055 892/00056 892/00057 892/00059 892/00060 892/00074 892/00075 892/00077 892/00137 892/00223 892/00252 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259

9803/3400

Section 1

Page No. Bonded Washer 3-7 Bonded Washer 3-7 Bonded Washer 3 - 6/3 - 7 Bonded Washer 3-7 Adapter 3-7 Adapter 3-7 Adapter 3 - 6/3 - 7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-6 JCB Threadlocker and sealer 4-1 JCB Threadlocker 4-1 JCB Threadlocker and Sealer (HS) 4-1 JCB Retainer (High Strength) 4-1 JCB High Strength Threadlocker 4-1 JCB Multi-Gasket 4-1 JCB Activator (Aerosol) 4-1 JCB Activator (Bottle) 4-1 Hand Cleaner 3-2 Flank Drive Socket 3-5 Speed Sensor Test Lead 3-5 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Pressure Test Adapter 3-6 Adapter 3-6 'T' Adapter 3-8 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 'T' Adapter 3-8 M6 x 16mm Rivet Nut 3-2 M6 x 19mm Rivet Nut 3-2 M8 x 21mm Rivet Nut 3-2 M8 x 18mm Rivet Nut 3-2 M10 x 23mm Rivet Nut 3-2 M10 x 26mm Rivet Nut 3-2 'T' Adapter 3-8 'T' Adapter 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Female Connector 3-8 Female Connector 3-8 Female Connector 3-8 Hose 3-7 Hand Pump 3-7 A.R.V Test Block - Husco 3-7 Pressure Test Kit 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6

892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00706 892/00842 892/00843 892/00844 892//00845 892/00846 892/00847 892/00848 892/00849 892/00923 * 892/00924 926/15500 992/09300 992/09400 992/09500 992/09600 992/12300 992/12400 992/12600 992/12800 992/12801 993/68100 993/85700

3-1 Page No. Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test 'T' Adapter 3 - 6/3 - 7 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 Flow Monitoring Unit 3-6 Sensor Head 3-6 Load Valve 3-6 Adapter 3-6 Adapter 3-6 Adapter 3-7 Adapter 3-6 Adapter 3-6 Adapter 3-6 Gauge 3-7 Gauge 3-7 AVO Meter 3-5 Shunt 3-5 Tool Kit Case 3-5 Tachometer 3-5 Hydraulic Oil Temperature Probe 3-5 Surface Temperature Probe 3-5 Test Probe 3-7 Glass Lifter 3-3 Folding Stand for Holding Glass 3-2 Long Knife 3-4 Cartridge Gun 3-2 Glass Extractor (Handles) 3-3 Nylon Spatula 3-4 Wire Starter 3-3 Braided Cutting Wire 3-4 A.R.V Test Block - Commercial Hyd. 3 - 7 Psion Walkabout 3-5 Rubber Spacer Blocks 3-4 Spanner 3-7 Spanner 3-7 Spanner 3-7 Spanner 3-7 12V Mobile Oven 3-2 240V Static Oven -2 Cartridge 3-3 240V Static Oven -6 Cartridge 3-3 Cut-Out Knife 3-3 â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Blades 3-3 Slide Hammer Kit 3-4 Battery tester 3-5

The following parts are replacement items for kits and would normally be included in the kit numbers quoted above. Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 892/00202 Replacement Gauge 892/00203 Replacement Gauge 892/00254 Replacement Hose

3 3 3 3

6 6 6 6

Issue 2

Section 1

General Information

3-2

Section 1 3-2

Service Tools

Section B - Body & Framework

826/01099 826/01101 826/01103 826/01102 826/01104 826/01105

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S1261210

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part 892/00845

number

Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g; 1 lb tub)

S186240

S186270

Folding Stand for Holding Glass - essential for preparing new glass prior to installation. 12V Mobile Oven - 1 cartridge capacity - required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300). JCB part number - 992/12300

JCB part 892/00843

number

S186280 S186250

9803/3400

Issue 1

Section 1 3-3

General Information

Section 1

Service Tools

3-3

Section B - Body & Framework (contâ&#x20AC;&#x2122;d)

240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

JCB part number: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V

JCB part number - 892/00842

S186300

S186260

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-Out Knife - used to remove broken glass. JCB part number - 992/12800 JCB part number - 892/00848

S186310

S186340

'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. JCB part number - 892/00846 S186320

9803/3400

S186350

Issue 1

Section 1

General Information

Section 1

Service Tools

3-4

Section B - Body & Framework (contâ&#x20AC;&#x2122;d)

Long Knife - used to give extended reach for normally inaccessible areas.

Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

JCB part number - 892/00844 JCB part number - 892/00849 (approx 25 m length)

S186360

S186330

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 (unit quantity = 500 off) Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. JCB part number - 892/00847 *

S186550

S186470-V1

Slide Hammer Kit - 993/68100 1 :993/68101 Slide Hammer 2 :993/68102 End Stops 3 :993/68103 Adaptor - M20 x 5/8" UNF 4 :993/68104 Adaptor - M20 x 1" UNF 5 :993/68105 Adaptor - M20 x M20

6 7 8 9 * 10 11

:993/68106 :993/68107 :993/68108 :993/68109 :993/68110 :993/68111 2

Adaptor - M20 x M24 Bar - M20 x M20 X 800MM Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x M16 Adaptor - M20 x 1/2" UNF 2 5

9 10 8 7

S196910

9803/3400

Issue 3*

Section 1

General Information

3-5

Section 1 3-5

Service Tools

Section C - Electrics

239510

993/85700

Battery Tester

* S188231

AVO Test Kit 1 2 3 4 5 6

892/00283 892/00281 892/00286 892/00284 892/00282 892/00285

Tool Kit Case AVO Meter Surface Temperature Probe Venture Microtach Digital Tachometer 100 Amp Shunt - Open Type Hydraulic Temperature Probe

A437530

331/27987

Flank Drive Socket

1 2

4 3

A437560

1 2

892/00924 892/00931

9803/3400

Psion Walkabout Psion Service Software Lead

721/11069

Speed Sensor Test Lead

Issue 4*

Section 1

General Information

Section 1

Service Tools

3-6

Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit 892/00253

Pressure Test Kit

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

Replacement Gauge 0-400 bar (0-400 lbf/in2)

892/00254

Replacement Hose

188120

188130

Pressure Test Adapters

Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265

200140

1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSPP x Test Point

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point

Flow Test Equipment

188150

9803/3400

892/00268 892/00269 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277

Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP

Issue 1

Section 1

General Information

Section 1

Service Tools

3-7

Section E - Hydraulics

220840

S270650

892/00252 Test Block for A. R. V. - Husco valves 892/00923 Test Block for A. R. V. - Commercial Hydraulic valves

193850

188140

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Bonded Washers 1406/0011 1406/0018 1406/0021 1406/0029

1/4 in BSP 1/2 in BSP 3/4 in BSP 1.1/4 in BSP

193860 193930

Male Adapters - BSP x BSP 1606/0003 1604/0003 1606/0004 1606/0007 1604/0004 1606/0008 1606/0009 1604/0006

9803/3400

3/8 in x 1/4 in 3/8 in x 3/8 in 1/2 in x 1/4 in 1/2 in x 3/8 in 1/2 in x 1/2 in 3/4 in x 3/8 in 3/4 in x 1/2 in 3/4 in x 3/4 in

Hexagon Spanners for Ram Pistons and End Caps 992/09300 992/09400 992/09500 992/09600

55 mm A/F 65 mm A/F 75 mm A/F 85 mm A/F

Issue 1

Section 1

General Information

Section 1

Service Tools

3-8

Section E - Hydraulics

193880 193870

Male Cone Blanking Plug Female Cone Blanking Plug 892/00055 892/00056 892/00057 892/00059 892/00060

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

1/4 in BSP 3/8 in BSP 1/2 in BSP 3/4 in BSP 1 in BSP'T'

1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP

193890

'T' Adapters 892/00047 892/00048 816/50043 816/60096

9803/3400

193900

Female Connectors 3/8 in BSP (A) x 1/4 in BSP (B) 1/2 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B)

892/00074 892/00075 892/00077

3/8 in BSP x 3/8 in BSP 1/2 in BSP x 1/2 in BSP 3/4 in BSP x 3/4 in BSP

Issue 1

Section 1 4-1

General Information

Section 1 4-1

Sealing and Retaining Compounds

Sealing and Retaining Compounds JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.

4102/1212

50ml

A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/0551

50ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter.

4101/0250 4101/0251

10ml 50ml

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use on threads larger than 50mm dia.

4101/0451

50ml

4104/0251 4104/0253

(1ltr) Bottle

400ml

Activator

A cleaning primer which speeds the curing rate of anaerobic products. (200ml)

Cleaner / Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

For one pane of glass, comprises items marked † below plus applicator nozzle etc.

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1206 4104/1203

30 ml 250 g

† Black Primer 206J

For direct glazing

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1538

Aerosol

Direct Glazing Kit

9803/3400

Issue 2

Care & Safety

Section 2

Contents

9803/3400

Page No.

Safety Notices

1-1

General

2-1

General Safety

3-1

Operating Safety

4-1

Maintenance Safety

5-1

Issue 1

Section 2

Care & Safety

1-1

Safety Notices

Section 2 1-1

In this manual and on the machine there are safety notices. Each notice starts with a signal word The meanings of the signal words are given below.

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others could be killed or seriously injured. INT-1-2-2

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

! WARNING Study this Service Manual before carrying out any maintenance work on the machine. You must always understand and observe the relevant laws and regulations If you are unsure about anything, ask your JCB Distributor.

9803/3400

Issue 1

Care & Safety

Section 2

General

2-1

Section 2 2-1

Introduction This section of the Manual is intended to REMIND the operator of basic safety requirements when operating industrial machinery. It is not a complete list of hazards that may exist when operating or maintaining the Teletruk. SPECIFIC HAZARDS RELATING TO MAINTENANCE INSTRUCTIONS ARE DETAILED IN THE RELEVANT SECTIONS OF THIS MANUAL.

Safety First - Yours And Other Peopleâ&#x20AC;&#x2122;s All industrial equipment can be hazardous. When a machine is properly maintained, it is a safe machine to work with. But when it is poorly maintained it can become a danger to you (the operator) and others. In this Manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your supervisor or JCB Distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them. Do not work with the machine until you are sure you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE INT-1-3-1/1

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General Safety

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Section 2 3-1

! WARNING Manual. You and others can be injured if you maintain the machine without first studying this Manual. Read the safety instructions before maintaining the machine. If you do not understand anything, ask your supervisor or JCB Distributor to explain it. Keep this Manual clean and in good condition. GEN 10-1

! WARNING Clothing. You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. INT-1-3-6

! WARNING Care and Alertness. All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. INT-1-3-5

! WARNING Fires. If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus. INT-3-2-7/1

! WARNING Alcohol and Drugs. It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness. INT-1-3-9

! CAUTION Regulations. Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3

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Operating Safety

4-1

! WARNING Decals. You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary. INT-1-3-4

! WARNING Machine Condition. A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this Manual are completed before using the machine. INT-2-1-2

! WARNING

! DANGER The Teletruk is installed with a Roll Over Protection Structure (ROPS) to ISO 3471 1994, and an Over Head Guard (OHG) to ISO 6055 1979. You could be killed or seriously injured if you operate this machine with a damaged or missing ROPS/OHG. If the ROPS/OHG has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/OHG certification. 12-5-1-2

! WARNING Training. Operators and Service Staff should be trained in the Safety Guidelines for the normal use of Telescopic Lift Trucks. 12-1-1-5

Practice. You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practice away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. INT-2-1-1

! WARNING Seat Belts. The operatorâ&#x20AC;&#x2122;s enclosure is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 12-1-1-4

! WARNING Controls. You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab. INT-2-1-3

! WARNING Visibility. Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you cannot see properly. INT-2-1-11

! WARNING Passengers. Passengers in or on the machine can cause accidents. The Teletruk is a one man machine. Do not carry passengers. INT-2-2-2

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Maintenance Safety

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! WARNING Raised Attachments. Raised attachments can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked.

Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings. INT-3-3-2

INT-1-3-8

! WARNING Raised Machine. NEVER position yourself or any part of you body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

! WARNING Metal Splinters. You can be injured by flying metal splinters when driving pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses. INT-3-1-3

! WARNING

INT-3-3-7/1

! WARNING Soft Ground. A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

! WARNING Lifting Equipment. You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

! WARNING Repairs. Do not try to do repairs or any other type of maintenance work you do not understand. JCB Distributor Engineers have been trained in all aspects of the Teletruk. 12-1-1-1

! WARNING Modifications and Welding. Non-approved modifications can cause injury and damage. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact you JCB Distributor for advice before modifying the machine. INT-3-1-2/1

! WARNING Hydraulic Fluid. Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put you face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. INT-3-1-10/1

! WARNING Hydraulic Pressure. Hydraulic fluid at pressure can injure you. Make the machine safe before connecting or disconnecting couplings; lower the payload to the ground, stop the engine then operate the hydraulic controls a few times to vent residual hydraulic pressure from the system.

5-1

Electrical Circuits. Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

Do not disconnect the battery while the engine is running otherwise the electrical circuits may be damaged. INT-3-1-14

! WARNING Communications. Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5

! CAUTION ‘O’ rings, Seals and Gaskets. Badly fitted, damaged or rotted ‘O’ rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed, unless otherwise instructed. Do not use Trichloroethane or paint thinners near ‘O’ rings and seals. INT-3-2-12

! CAUTION Cleaning. Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

! CAUTION Machine Modifications. This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of the requirements. For advice consult your JCB Distributor. I2-1-1-3

12-1-1-2

! WARNING Hydraulic Hoses. Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers 9803/3400

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! CAUTION Arc Welding. Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is fitted. Make sure that the welding earth return path is kept as short as possible. This prevents high currents being induced in the machine chassis or wiring harnesses. If the machine is equipped with electronic control units (E.C.U.s), then disconnect them before welding. Failure to disconnect the E.C.U.s could result in irreparable damage to the electronic components. INT-3-1-15

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Section 3

Routine Maintenance

Section 3 i

Contents Fluids, Capacities and Lubricants

1-1

Lubricants Health and Safety

1-2

Service Schedules

2-1

Operatorâ&#x20AC;&#x2122;s Enclosure and Seat Belt

3-1

* Cleaning

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the Machine

3-2

Greasing

4-1

Electrics Battery Safety Checking the Electrolyte Level Checking the Battery Terminals Warning Symbols

5-1 5-2 5-2 5-2

Hydraulic System Checking the Fluid Level Checking for Leaks Checking the Hoses and Pipework Filter - Removal and Replacement

6-1 6-1 6-1 6-2

Air Filter Changing the Elements

7-1

Cooling System Coolant Mixture * Checking the Coolant Level - Diesel Engine

8-1 8-2

Engine Oil Checking the Oil Level (Diesel) Changing the Oil and Filter (Diesel)

9-1 9-2

Fuel System - Diesel Types of Fuel Filling the Tank Draining the Sedimenter Bleeding the Diesel Fuel System (if required)

10 - 1 10 - 1 10 - 2 10 - 3

Fuel System - LPG General Type of LPG Filling the LPG Tank

11 - 1 11 - 1 11 - 2

Fan Belt (Diesel and LPG Engine Checking the Fan Belt Tension

12 - 1

Transmission Steer Spindle (4x4 Option Only)

13 - 1

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Section 3 1-1

1-1

Fluids, Capacities and Lubricants ITEM

CAPACITY

FLUID/LUBRICANT

SPECIFICATION

Engine Oil NAT ASP Up to SN892816

8.2 litres

JCB 10W/30 Multigrade

SAE10W/30 API CF4/SG

From SN892817

10 litres

JCB Extreme Performance Engine Oil 15W/40

CH4/SJ (ACES E5-B3-A3)

Turbo

10 litres

JCB Extreme Performance Engine Oil 15W/40

CH4/SJ (ACES E5-B3-A3)

LPG

8.2 litres

JCB 10W/30 Multigrade

SAE10W/30 API CF4/SG

Hydraulic System

55 litres

JCB 15W/40 Multigrade JCB 10W/30 Multigrade

API CF4/SG 15W/40 API CF4/SG 10W/30

Cooling System

5.5 litres Antifreeze 11 litres total coolant mixture

JCB Universal Antifreeze/water (see Coolant Mixtures)

ASTM D3306-74

Fuel System

90 litres

Diesel oil (see Types of Fuel) Liquid Petroleum Gas (LPG) (see LPG Fuel System)

ASTM D975-66T Nos. 1D, 2D

Grease Points

JCB Special HP or MPL Grease

Lithium based, No. 2 consistency

Boom Runways

Waxoyl

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It is most important that you read and understand this information and the publications referred to. Make sure that all of your colleagues who are concerned with lubricants read it too.

Lubricants - Health and Safety Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. Low viscosity oils are more likely to do this, therefore particular care is necessary in handling used oils which can be diluted with fuel contamination.

Note the following when removing engine oil from skin: a Wash your skin thoroughly with soap and water. b Using a nail brush will help. c Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel or paraffin for washing. e Avoid skin contact with oil soaked clothing. f Don't keep oily rags in pockets. g Wash dirty clothing before re-use. h Throw away oil-soaked shoes.

First Aid - Oil Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, and note the following:

Swallowing. If oil is swallowed you should not induce vomiting. Get medical advice.

Storage

Skin In the case of excessive skin contact you should wash with soap and water.

Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

Waste Disposal Spillage All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Handling

Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self contained breathing apparatus.

New Oil

! WARNING

There are no special precautions needed for the handling or use of new oil, beside normal care and hygiene practices.

Do not use water to put out an oil fire. This will only spread it because oil floats on water.

Used Oil

Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus.

Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

7-3-1-3/1

Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used engine oils.

Apply a barrier cream to the skin before handling used engine oil.

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Routine Maintenance

Section 3 2-1

Service Schedules

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the schedules are done to keep the machine in a safe and efficient working condition. The schedules are based on machine running hours. Keep a regular check on the hourmeter readings. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

z = Initial 250 Hour Check Only Pre-start Cold Checks Service Points and Fluid Levels

= Regular Maintenance Check Operation

ENGINE (LPG and Diesel) Oil and Filter (see note) - Change Air Cleaner Dust Valve - Clean Air Cleaner Outer Element - Change Air Cleaner Inner Element - Change Fuel Filter (Diesel only) - Change Coolant Level - Check Antifreeze Strength - Check Air Cleaner Hose - Security Fuel Sedimenter (Diesel only) - Drain Fan Belt Tension/Condition - Check Valve Clearances (Diesel only) - Check and Adjust Engine Mount Security - Check Radiator Matrix - Clean Radiator Hose - Condition Spark Plugs (LPG only) - Clean/Replace Clean turbo charger impeller casing and turbo charger compressor casing Fit new engine breather (HR build only)

250 Hr

500 Hr

1000 Hr

2000 Hr

z z z z z z

z z z

Note: If operating under arduous conditions change the engine oil filter every 250 hours TRANSMISSION AND AXLES Wheel Nuts Security Tyre Pressures and Condition Rear Wheel Hub Bearings and Pins Steer Linkage for Wear Steer Spindle (4 Wheel Drive Option Only) HYDRAULICS Suction Strainer Oil Sample/Change Oil Level Oil Filter Ram Piston Rods for Damage or Leakage Hoses & Pipework - Damage or Leaks Motor Mounting Bolts Security

Hydraulic Oil ELECTRICS Wiring for Chafing Battery Terminals for Condition and Tightness

- Check - Check - Check - Check - Check

- Clean - Check - Change - Check - Check - Check - Change

z z z z z

- Check - Check

z z

z z z z z z z

BODY AND FRAMEWORK All Pivot Pins - Check and Grease All Hinges - Grease * Wear Pad Runways - Waxoyl Seat/Seat Belt Security and Condition - Check Bodywork for Damage - Check * Windscreen Washer Fluid Level - Fill Check boom rear wear pad mounting bolts for tightness (56Nm, 41lbf ft)

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Operation

Functional Test and Final Inspection

Operation

2000 Hr

1000 Hr

2000 Hr

z z z z

- Check - Check

- Check - Check - Check and Adjust - Check and Adjust - Check - Check - Check

z z z

- Check - Check

z z

- Check - Check/Calibrate

z z

- Check

z z

- Check

ELECTRICS

ATTACHMENTS Attachment Operation Forks Condition/Security

Correct Load Chart For Attachment Fitted

- Check - Check

GENERAL

Fluid Leaks (e.g. coolant, engine, oil, fuel, hydraulic oil, etc.)

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1000 Hr

500 Hr

BRAKES Parking Brake Operation Foot Brake Operation

Load Moment Indicator

500 Hr

250 Hr

TRANSMISSION AND AXLES Transmission for Vibration/Noise Transmission Pressures

* All Electrical Equipment Operation

250 Hr

Check

ENGINE Idle Speed - Check and Adjust Maximum No Load Speed - Check and Adjust Exhaust Smoke - Check Engine for Vibration/Noise - Check Fuel System For Leaks (LPG only) - Check Fuel System - Fuel Lock, Vapourisor Carburettor (LPG only) - Check

HYDRAULICS Operation of All Services Operation of Carriage Tilt/Crowd and Self Level MRV Pressure * Steer Circuit Pressure Steer Circuit Operation Hoses for Damage and Leaks Pipework for Damage and Leaks

2-2

Service Schedules

Pre-start Cold Checks Service Points and Fluid Levels PAINTWORK Condition

Section 3

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Section 3

Routine Maintenance Operatorâ&#x20AC;&#x2122;s Enclosure and Seat Belt

3-1

Section 3 3-1

Checking the Operatorâ&#x20AC;&#x2122;s Enclosure Carry out a thorough inspection of the operators enclosure. If any damage is discovered, contact your JCB distributor.

Checking Seat Belt Condition and Security When checking the seat belt, look for signs of fraying and stretching. Make sure the stitching is not loose or damaged. Make sure the buckle assembly is working correctly and not damaged. Install a new belt every three years. Make sure the belt mounting bolts are undamaged, correctly installed and fully tightened.

! WARNING Replace the seat belt with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Install a new seat belt every three years regardless of condition. 2-3-1-8

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Routine Maintenance

Section 3

Cleaning the Machine

3-2

Park the machine on firm level ground, engage the parking brake, lower the boom to the ground, switch OFF the engine and remove the starter key. Allow the engine and exhaust system to cool. Clean the machine using water and/or steam. Avoid using neat detergent - always dilute detergents as per the manufacturerâ&#x20AC;&#x2122;s recommendations, otherwise damage to the paint finish may occur. Always grease the machine after pressure washing or steam cleaning. Always adhere to local regulations regarding the disposal of debris created from machine cleaning. Make sure there are no unprotected electrical wires before proceeding. 3.5D 2 wheel drive and 3.0D HL machines Note: Excessive power washing can damage seals and bearings. Do not direct high power water jets directly at oil seals or universal joints. Do not steam clean or power wash inside the cab. Take care when cleaning electrical components and connectors. Pay particular attention to the following: 1

Remove debris and loose articles from inside the cab.

If the radiator tubes/fins get clogged the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure. 3.5D and 3.0D HL machines, open the engine cover and undo the bolts A and remove the panel B to clean engine side od radiator. To clean rear side of radiator gain access through the counter weight opening.

Debris can collect under the boom. Remove especially all combustible material.

Do not allow debris to accumulate around the engine, pay particular attention to the exhaust area, remove all combustible material.

Throughly dry piston rams and protect with clean transmission or hydraulic oil if necessary.

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Routine Maintenance

Section 3

Greasing

4-1

General

Carriage

The Teletruk must be greased regularly to keep it working efficiently. Regular greasing will also increase the machineâ&#x20AC;&#x2122;s working life.

The six grease points on the carriage are as follows:

Grease of the correct specification should be applied with a grease gun (except for the boom pads runway, which should have Waxoyl applied along its length). Stop greasing when fresh grease appears at the joint. Use JCB High Pressure (HP) grease for improved machine reliability.

A B C D E F

Right Carriage Pivot. Right Carriage Ram Upper Pivot. Right Carriage Ram Lower Pivot. Left Carriage Pivot. Left Carriage Ram Lower Pivot. Left Carriage Ram Upper Pivot.

Location of Greasing Points

For the purposes of greasing, the Teletruk is split into five separate sections: A B C D E

Carriage. Boom. Rear steer axle. Sideshift. Boom pads runway.

Note: Refer to the following figures for the location of each individual grease point.

A Greasing Procedure 1

After raising or extending the boom, ensure that chocks or suitable supports are used to prevent it from falling. 12-5-1-3

Raise and extend the boom.

Apply the park brake.

Stop the engine and remove the ignition key.

Remove the dust caps.

Apply grease to the grease points and apply Waxoyl as detailed in the relevant Servicing Schedule.

Count off each greasing point in turn until all greasing points have been lubricated.

Replace the dust caps as required.

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C C054860

Park the Teletruk on firm level ground.

! WARNING

Boom Remove the rear boom cover. The six grease nipples and Waxoyl points on the boom are as follows: A B C D E F

Right Boom Pivot. Left Boom Pivot. Boom Pads Runway (Waxoyl). Raise/Lower Ram Lower Pivot. Raise/Lower Ram Upper Pivot. Compensation Ram Upper Pivot.

Compensation Ram Lower Pivot. Issue 4*

Section 3

Routine Maintenance

Section 3

Greasing

4-2

Rear Axle

Sideshift (Optional)

2 Wheel Drive Machines

The two grease points on the sideshift mechanism (if fitted) are as follows:

The six grease points on the rear axle are as follows: A B C D E F

Left Stub Shaft (Every 500 Hrs only). Left Steering Link Outer Pivot. Left Steering Link Inner Pivot. Right Steering Link Inner Pivot. Right Steering Link Outer Pivot. Right Stub Shaft (Every 500 Hrs only).

E F

Top Rail Right Side. Top Rail Left Side.

Apply a smear of grease to the Bottom Rail G.

A401730-V3

4x4 Machines The eight grease points on the rear axle are as follows: A B C D

Stub Shaft (left and right). Steering Link Outer Pivot (left and right). Steering Link Inner Pivot (left and right). Swivel trunnion bearings (left and right).

B C D * 3.0D 4x4

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* 3.5D 4x4

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Section 3

Routine Maintenance Electrics

5-1

Safety

Section 3 5-1

! WARNING

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks or flame. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear safety glasses and suitable clothing. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, install the positive (+) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.

! WARNING Battery. A battery with a frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged. INT-3-1-7

! WARNING Electrolyte. Battery electrolyte is toxic and corrosive. Do not breathe the gasses given off by the battery. Keep the electrolyte away from clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1/2

! CAUTION Damaged or spent batteries and any residue from fires or spillages should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

First Aid - Electrolyte Do the following if electrolyte: Gets in your eyes: Immediately flush with tepid water for 15 minutes, always get medical attention. Is swallowed: Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical advise. Gets onto your skin: Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

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Electrics

5-2

Checking the Electrolyte Level Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below. 1 2 3 4 5 6 7 8 9

Park the machine on firm level ground and lower the boom. Apply the park brake. Stop the engine and remove the ignition key. Switch the battery isolator to off and remove the key. Remove the battery cell cover(s) A. Make sure the level in each cell is 6 mm (0.25 in.) above the plates. If necessary, top up with distilled water. Refit the battery cell cover(s). Insert the key and switch the battery isolator to on.

6 mm

! WARNING

A089660-1

Do not top up the battery with acid. The electrolyte could boil over and burn you. 2-3-4-6

Checking the Battery Terminals

Warning Symbols

Park the Teletruk on firm level ground and lower the boom.

The following warning symbols may be found on the battery.

Apply the park brake and select neutral.

Symbol

Stop the engine and remove the ignition key.

Switch the battery isolator to off and remove the key.

Open the daily inspection cover (Refer to Refer to Section B).

Meaning Keep away from children.

Disconnect each battery terminal in turn and thoroughly clean the terminal and clamp.

Refit the battery terminals and fully tighten.

Protect the terminals and clamps with petroleum jelly to prevent corrosion.

Close the daily inspection cover.

Shield eyes.

No smoking, no naked flames, no sparks.

Explosive Gas.

10 Insert the key and switch the battery isolator to on. Battery acid.

Note operating instructions.

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Section 3

Electrics

5-3

Battery Isolator To disconnect the battery from the machine electrics a battery isolator has been fitted.

Note: On some machines the isolator is fitted in the counterweight.

! CAUTION Except in an emergency, do not use the battery isolator to switch OFF the engine. Failure to comply may result in damage to the electrical circuits.

INT-3-2-13

At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on. 1

To isolate the battery turn the battery isolator key A in an counter-clockwise direction B and remove. Keep the key in a safe place and available for when the machine is next required.

324690

To connect the battery insert the key A and turn in a clockwise direction C.

! CAUTION Arc Welding. Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components.

The battery must still be disconnected even if a battery isolator is fitted. Make sure that the welding earth return path is kept as short as possible. This prevents high currents being induced in the machine chassis or wiring harnesses. If the machine is equipped with electronic control units (E.C.U.s), then disconnect them before welding. Failure to disconnect the E.C.U.s could result in irreparable damage to the electronic components.

C053610

INT-3-1-15

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Section 3

Routine Maintenance

Section 3

Hydraulic System

6-1

Checking the Oil Level 1 2 3 4

Park the Teletruk on firm level ground and lower the boom. Apply the park brake and select neutral. Stop the engine and remove the ignition key. Check the level at the sight gauge A. If necessary, top up with the correct hydraulic oil through filler B (Refer to Fluids, Capacities and Lubricants).

! CAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your Distributor immediately. U/12-5-1-4

Checking for Leaks

A C053630

! WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. INT-3-1-10/1

If pools of oil appear below or on the machine, find the cause of the leak as follows: 1 2

3 4

Thoroughly clean and dry the area. Start the engine and operate the relevant system a few times to locate the leak. Inspect the area to find the cause of the leak. If necessary, hold cardboard next to the suspected component to help identify the location. Stop the engine and dissipate the hydraulic pressure from the system by operating the controls a few times. Rectify the leak as required.

Notice: If necessary, report the fault to your JCB Distributor for assistance in carrying out the repair.

Checking the Hoses and Pipework ! WARNING After raising or extending the boom, ensure that blocks or suitable supports are used to prevent it from falling. 12-5-1-3

Tilt the cab forward or position the boom or steering as required to gain access to each hose or pipe.

Inspect each hose in turn. Make sure they are free from cuts, signs of leakage, bulging, fraying or any other damage.

Inspect each pipe in turn. Make sure they are free from cracks, signs of leakage, corrosion or any other damage.

Position the boom in its retracted and lowered position.

Apply the park brake and stop the engine. Remove the ignition key.

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Issue 2*

Section 3

Routine Maintenance

Section 3

Hydraulic System

6-2

Filter - Removal and Replacement Removal

Replacement

! WARNING

Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake engaged and the transmission is in neutral. Disconnect the battery. Chock both sides of all four wheels.

Ensure the filter head B is clean.

Using clean hydraulic oil, fill the new filter canister (allowing time for the oil to pass through the filter element) and lubricate seal C. (Seal C is not shown but is located between the canister A and the head B.)

5-3-2-1/1

Extend and lower boom to its lowest position.

Install the new filter canister hand tight only, and ensure it is clean and dry.

Make the machine safe by stopping the engine, removing the key, and chocking the wheels.

Open front cover (Refer to Access Procedures for Maintenance, Section B)

Start the machine and operate the boom controls to pressurize the system. Ensure the boom is left fully extended with the carriage on the ground.

Stop the engine and remove the ignition key.

Inspect the filter canister for leaks.

Check the hydraulic oil level and top up if necessary.

Refit the front cover (Refer to Section B).

! WARNING Hydraulic Pressure It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to dissipate. Keep face and hands well clear of pressurized hydraulic oil and wear protective glasses. 4

Ensure that all hydraulic pressure is released from the system (By operating the lift lever).

Remove the old canister A, using a chain wrench if necessary.

B C A

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Issue 2*

Section 3

Routine Maintenance Air Filter

7-1

Section 3 7-1

Changing the Elements ! CAUTION

Depress clips B and lift off cover C. Remove outer element D. Take care not to tap or knock the element. If the inner element is to be changed, lift up pulls E and remove inner element F.

Clean inside the canister H, cover C and dust valve J.

Insert the new elements into the canister, pushing them firmly in so that seals G and K are fully seated. Fit cover C with dust valve J at the bottom. Push the cover firmly into position and make sure it is secured by clips B.

Make sure that the wire is connected to the Air Filter Blocked switch.

The outer element must be replaced with a new one immediately if the warning light on the instrument panel illuminates. U-2-3-3-1

Notice: Do not attempt to wash or clean the elements - they must only be renewed. Do not run the engine with the dust valve J removed. A new inner element must be fitted at least every third time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed. 1

Stop the engine.

Open the daily inspection cover (Refer to Section B).

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Issue 3*

Section 3

Routine Maintenance Cooling System

8-1

Section 3 8-1

Coolant Mixtures *To prevent the coolant freezing in cold conditions, antifreeze must be added. The protection provided by JCB Universal Antifreeze is shown below. Solution 50%

Maintains circulation down to deg C deg F -33 -27

Protects against damage down to deg C deg F -45 -49

Never use less than 45% antifreeze solution otherwise there will not be enough corrosion protection. Never use more than 50% antifreeze solution otherwise the cooling system may be damaged. Leave the antifreeze in all the year round as it gives protection against corrosion. Check the strength of antifreeze solution at least once a year, preferably at the start of the cold period. Always renew the antifreeze every two years. A 50% antifreeze solution should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point.

! WARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling neat or diluted antifreeze. 7-3-4-4

! WARNING

The cooling system is pressurized when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system. 2-3-3-3

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Issue 3*

Section 3

Routine Maintenance

Section 3 8-2

Cooling System

8-2

Checking the Coolant Level ! WARNING

The cooling system is pressurized when the coolant is hot. Hot coolant will burn. Make sure the engine is switched off and sufficiently cooled before checking the coolant level or draining the system. INT-2-3-3-3

! CAUTION

Antifreeze can be harmful. Obey the manufacturerâ&#x20AC;&#x2122;s instructions when handling neat or diluted antifreeze. 7-3-4-4

Park the Teletruk on firm level ground and lower the boom.

Apply the park brake and select neutral.

Stop the engine and remove the ignition key. Let the engine cool down before proceeding.

All 2.0/2.5/3.0 Machines and 3.5D 4x4 Open the daily inspection cover (Refer to Access Procedures for Maintenance). b All 3.5 Machines (Except 3.5D 4x4) and 3.0D HL Open the rear daily inspection cover (Refer to Access Procedures for Maintenance).

Check that the coolant level is within the High and Low marks on the expansion tank B.

If necessary, top up the system with a suitable mixture as follows: a b c d e

B 281340

All 2.0/2.5/3.0 Machines

Top up the expansion tank through filler cap A. Refit the filler cap A and make sure it is tight. Close the daily inspection cover. Run the engine for a few minutes to raise the coolant to working temperature and pressure. Stop the engine and top up the system again if required. Check for leaks.

All 3.5 Machines (Except 3.5D 4x4) and 3.0D HL 760220-V1

3.5D 4x4 Machines 9803/3400

Issue 4*

Section 3

Routine Maintenance

Section 3

Engine Oil

9-2

Changing the Oil and Filter ! WARNING Hot oil and engine components can burn. Make sure the engine is turned off and sufficiently cooled before attempting this job.

INT-2-3-3-2

Park the Teletruk on firm level ground and lower the boom.

*2 Machines with LPG engines, turn the fuel valve OFF and run the engine until it stalls. 3

Apply the park brake and select neutral.

Stop the engine and remove the ignition key.

Open the daily inspection cover (Refer to Section B).

Place a suitable container under the machine to catch the oil.

Remove the drain plug and allow oil to drain into container.

After emptying the sump replace the drain plug.

E G 327530

Unscrew the filter canister E, using a chain wrench if necessary. Remember that it will contain some oil.

10 Clean filter head on the engine. 11 Add clean engine oil to the new filter canister. Allow time for the oil to pass through the filter element. 12 Smear the seal G on the new filter canister with clean engine oil. 13 Screw in the new filter canister - hand tight only. 14 Fill the engine with the recommended oil, to the MAX mark on the dipstick A, through the filler point B. Wipe off any spilt oil, refit the filler cap and make sure it is secure. 15 Make sure the engine will not start by removing the engine shut-off solenoid (ESOS) fuse, diesel engine machines only. Turn the engine using the starter key until the oil pressure warning light is extinguished. 16 Refit the engine shut-off solenoid fuse, diesel engine machines only. LPG engines, slowly open the fuel valve. Start the engine and check for leaks. When the engine has cooled, check the oil level and, if necessary, top up with clean engine oil. 17 Close and secure the engine compartment rear door and hinged top cover.

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Issue 2*

Section 3 10 - 1

Routine Maintenance

Section 3 10 - 1

Fuel System - Diesel

*Types of Fuel

Low Temperature Fuels

Use good quality diesel fuel to get the correct power and performance from your engine. The recommended fuel specification for JCB engines is given below.

Special winter fuels may be available for engine operation at temperatures below 0 °C (32 °F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter).

Cetane Number: Viscosity: Density: Sulphur: Distillation:

45 (minimum) 2.5/4.5 Centistokes at 40 °C (104 °F) 0.835/0.855 kg/litre (0.872/0.904 lb/pint) 0.5% of mass (maximum) 85% at 350 °C (662 °F)

Flow improvers may also be available. These can be added to the fuel to reduce wax formation.

Petrol

Cetane Number Indicates ignition performance. Fuel with a low cetane number can cause cold start problems and affect combustion.

! WARNING

Do not use petrol in this engine. Do not mix petrol with the diesel fuel. In storage tanks the petrol could rise to the top and form flammable vapors. INT-3-1-6

Viscosity

Filling the Tank Is the resistance to flow. If this is outside limits, the engine performance can be affected. Density Lower density will reduce engine power. Higher density will increase both engine power and exhaust smoke. Sulphur High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulfur fuel you must also use a highly alkaline engine lubricating oil; or change the normal oil more frequently.

! WARNING

Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refueling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions. INT-3-2-2

At the end of every working day, fill the tank through the filler A with the correct type of fuel. This will prevent condensation from developing in the fuel tank overnight.

Distillation This indicates the mixture of different hydrocarbons in the fuel. A high ratio of lightweight hydrocarbons can affect the combustion characteristics.

A 274850

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Issue 2*

Section 3

Routine Maintenance

10 - 2

Section 3

Fuel System - Diesel

Draining the Sedimenter 1

Park the Teletruk on firm level ground and lower the boom.

Apply the park brake and select neutral.

Stop the engine and remove the ignition key.

Open the daily inspection cover (Refer to Section B).

Drain off any water in the sediment bowl B by opening the tap A. Drain into a suitable container and dispose of in accordance with environmental regulations.

Re-tighten tap A.

Check for leaks.

Close the daily inspection cover.

10 - 2

B A C053420

9803/3400

Issue 3*

Section 3

Routine Maintenance

Section 3

Fuel System - Diesel

10 - 3

Bleeding the Diesel Fuel System (if required) 1

Park the Teletruk on firm level ground and lower the boom.

Apply the park brake and select neutral.

Stop the engine and remove the ignition key.

Open the daily inspection cover (Refer to Access Procedures for Maintenance, Section B).

Make sure there is sufficient fuel in the tank.

Open the fuel injection pump vent valve A.

Operate the priming pump C or priming pump lever B slowly until fuel with no air flows freely from the valve, then close the valve.

Notice: If no fuel is moved when the priming lever B is operated then the pump diaphragm may have rested in a maximum lift position. To move the diaphragm, use the starter key to turn the engine slightly, then try the priming lever again. 8

Slacken the bleed plug on the sedimentor bowl and again operate the lift pump priming lever until fuel with no air flows freely from the plug, then tighten the plug. Remove the E.S.O.S. fuse to prevent the engine from starting.

B 281350

S255860

! WARNING To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment. Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.

When the engine is turning, keep clear of rotating parts. 2-3-3-8

Slacken each injector feed pipe in turn, at the injector, and operate the starter to turn the engine until air free fuel emits from the joint then re-tighten the pipe union.

Replace the E.S.O.S. fuse and start the engine. Check for smooth running. If the engine continues to run roughly, repeat the bleeding procedure.

Close the daily inspection cover.

9803/3400

Issue 4*

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