JCB ROBOT 1110T HF Service and Repair Manual

Copyright © 2004 JCB SERVICE. 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. World Class Customer Support 9803/9460-1 Publication No. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377 Section 3 Maintenance Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section J - Tracks Section K - Engine

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Page No. Contents Section 3 - Maintenance 3 - i 3 - i Routine Maintenance Service Requirements ............................................................................. 3 - 1 Introduction ......................................................................................... 3 - 1 Owner/Operator Support .................................................................... 3 - 1 Service/Maintenance Agreements ..................................................... 3 - 1 Lifting Regulations - Inspections and Tests ........................................ 3 - 1 Obtaining Replacement Parts ............................................................. 3 - 2 Health and Safety .................................................................................... 3 - 3 Lubricants ........................................................................................... 3 - 3 Battery ................................................................................................ 3 - 5 First Aid - Electrolyte .......................................................................... 3 - 5 Service Schedules ................................................................................... 3 - 7 Introduction ......................................................................................... 3 - 7 How to Use the Service Schedules .................................................... 3 - 7 Pre-start Cold Checks, Service Points and Fluid Levels .................... 3 - 8 Functional Test and Final Inspection ................................................ 3 - 10 Fluids, Lubricants and Capacities .......................................................... 3 - 12 Coolant Mixtures .............................................................................. 3 - 12 Cleaning the Machine ............................................................................ 3 - 14 Checking for Damage ............................................................................ 3 - 17 Seat Belt ................................................................................................ 3 - 18 Checking the Seat Belt Condition and Security ................................ 3 - 18 ROPS/FOPS Structure .......................................................................... 3 - 19 Checking the ROPS/FOPS Structure ............................................... 3 - 19 Boom Safety Strut ................................................................................. 3 - 20 Installing ........................................................................................... 3 - 20 Removing ......................................................................................... 3 - 21 Greasing ................................................................................................ 3 - 22 Greasing 10 Hours ........................................................................... 3 - 22 Every 50 Hours ................................................................................. 3 - 23 Oiling ..................................................................................................... 3 - 24 Every 500 Hours ............................................................................... 3 - 24 Access Panels ....................................................................................... 3 - 25 Engine Cover .................................................................................... 3 - 25 Rear Panel ....................................................................................... 3 - 25 Electrical System ................................................................................... 3 - 26 Battery .............................................................................................. 3 - 26 Jump Starting the Engine ................................................................. 3 - 27 Fuses and Relays ............................................................................. 3 - 29 Engine Air Filter ..................................................................................... 3 - 32 Cleaning the Air Filter Dust Valve ..................................................... 3 - 32 Changing the Elements .................................................................... 3 - 32 Engine ................................................................................................... 3 - 34 Checking the Oil Level ..................................................................... 3 - 34 Changing the Oil and Filter ............................................................... 3 - 34 Checking the Coolant Level ............................................................. 3 - 36 Changing the Coolant ....................................................................... 3 - 37 Front End Accessory Drive Belt ....................................................... 3 - 38 Fuel System ........................................................................................... 3 - 40 Types of Fuel .................................................................................... 3 - 40 Filling the Tank ................................................................................. 3 - 41 Draining the Primary Water Separator and Engine Fuel Filter ......... 3 - 42 Changing the Primary Water Separator Filter .................................. 3 - 43 Changing the Engine Fuel Filter Element ......................................... 3 - 44 Bleeding the System ........................................................................ 3 - 45

Section 3 - Maintenance Contents 3 - ii 3 - ii Page No. Contents Hydraulic System ................................................................................... 3 - 46 Checking the Hydraulic Fluid Level .................................................. 3 - 46 Changing the Hydraulic Return Filter ............................................... 3 - 47 Changing the Filter Element ............................................................. 3 - 48 Drive Chain Lubrication ......................................................................... 3 - 49 Checking the Oil Level ..................................................................... 3 - 49 Changing the Oil ............................................................................... 3 - 50 Tyres and Wheels .................................................................................. 3 - 51 Tyre Inflation ..................................................................................... 3 - 51 Checking the Wheel Nut Torques ..................................................... 3 - 51 Renewing Segments of Optional Non-Inflatable Tyres ..................... 3 - 52 Tracks .................................................................................................... 3 - 53 Track Adjustment .............................................................................. 3 - 53 Windscreen Washer (optional) .............................................................. 3 - 54 Checking the Level ........................................................................... 3 - 54 Storage .................................................................................................. 3 - 55 Storing the Machine .......................................................................... 3 - 55

Section 3 - Maintenance 3 - 1 3 - 1 9803-9460-1 Routine Maintenance Service Requirements Introduction T3-002 Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine. A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced. Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1 Giving your name, address and telephone number. 2 Quoting your machine model and serial number. 3 Date of purchase and hours of work. 4 Nature of the problem. Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements. Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details. Lifting Regulations - Inspections and Tests T3-003 Only your JCB Distributor can fully meet the requirements of the inspection and test parameters to suit UK Health and Safety Executive (H.S.E.) legal requirements along with providing Annual Inspections to meet your Insurance Company Policy conditions. Only your JCB Distributor has the ability to meet the definition described covering a "Competent Person" to

JCB ROBOT 1110T HF Service and Repair Manual

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