JCB 3.0D 4x4 Teletruk OEM Service & 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 9803/9510-04 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 3 Maintenance Service Manual - Teletruk 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 H - Steering Section K - Engine

Section 3 - Maintenance 3-0 3-0 9803/9510-04 Notes:

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 Fit for Purpose Tests for Lifting Equipment ............................................ 3-1 Obtaining Replacement Parts ................................................................ 3-1 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 ............................................................................ 3-8 Pre-start Cold Checks, Service Points and Fluid Levels ....................... 3-9 Functional Test and Final Inspection ................................................... 3-11 Fluids, Lubricants and Capacities ............................................................ 3-12 Coolant Mixtures ................................................................................. 3-13 Fuels .................................................................................................... 3-14 Prepare the Machine for Maintenance .................................................... 3-17 Introduction .......................................................................................... 3-17 How to Make the Machine Safe (Boom Lowered) ............................... 3-18 Cleaning the Machine .............................................................................. 3-19 Introduction .......................................................................................... 3-19 Preparing the Machine for Cleaning .................................................... 3-19 Cleaning the Machine .......................................................................... 3-20 Checking For Damage ............................................................................. 3-21 Check the Machine Body and Structure .............................................. 3-21 Check the Tyres .................................................................................. 3-21 Check the Seat and Seat Belt ............................................................. 3-22 Check the Hydraulic Hoses and Fittings ............................................. 3-22 Checking the ROPS/FOPS Structure .................................................. 3-22 Greasing .................................................................................................. 3-23 Introduction .......................................................................................... 3-23 Preparing the Machine for Greasing ................................................... 3-23 Carriage ............................................................................................... 3-24 Boom ................................................................................................... 3-24 Rear Axle ............................................................................................. 3-25 Sideshift Option ................................................................................... 3-25 Inner Boom .......................................................................................... 3-26 Access Panels ......................................................................................... 3-27 Operator's Enclosure/Cab ................................................................... 3-27 Daily Inspection Cover ........................................................................ 3-29 Front Cover ......................................................................................... 3-30 Daily Inspection Rear Cover ................................................................ 3-31 Belly Plate (4WD Machines) ................................................................ 3-32 Optional Trash Guard .......................................................................... 3-32 Brakes ..................................................................................................... 3-33 Park Brake ........................................................................................... 3-33 Electrical System ..................................................................................... 3-34 Battery ................................................................................................. 3-34 Jump Starting the Engine .................................................................... 3-35 Fuses ................................................................................................... 3-37 Relays ................................................................................................. 3-41 Bulbs ................................................................................................... 3-42

Section 3 - Maintenance Contents 3-ii 3-ii Page No. Contents Engine ..................................................................................................... 3-43 Oil and Filter (Perkins) ......................................................................... 3-43 Oil and Filter (Deutz 2011-L04W) ........................................................ 3-45 Air Filter (Perkins) ................................................................................ 3-47 Air Filter (Deutz 2011-L04W) ............................................................... 3-48 Fan Belt (Perkins) ................................................................................ 3-49 Alternator Drive Belt (Deutz 2011-L04W) ............................................ 3-50 Timing Belt ........................................................................................... 3-51 Cooling System ................................................................................... 3-52 Diesel Fuel System .................................................................................. 3-53 Introduction .......................................................................................... 3-53 Water Separator and Engine Fuel Filter .............................................. 3-53 Fuel Primer (Deutz 2011-L04W) .......................................................... 3-56 Bleeding the System ........................................................................... 3-57 LPG Fuel System .................................................................................... 3-58 General ................................................................................................ 3-58 Type of LPG ........................................................................................ 3-59 Filling the LPG Tank ............................................................................ 3-59 Changing the LPG Tank ...................................................................... 3-59 Hydraulic System ..................................................................................... 3-60 Introduction .......................................................................................... 3-60 Releasing the Hydraulic Pressure ....................................................... 3-61 Checking the Fluid Level ..................................................................... 3-62 Checking for Leaks .............................................................................. 3-63 Checking the Hoses and Pipework ..................................................... 3-63 Changing the Filter Element ................................................................ 3-64 Changing the Filter Element (Pal Filter) .............................................. 3-64 Tyres and Wheels .................................................................................... 3-65 General ................................................................................................ 3-65 Tyre Inflation ........................................................................................ 3-66 Changing a Wheel ............................................................................... 3-67 Forks ....................................................................................................... 3-69 Inspecting the Forks ............................................................................ 3-69 Changing the Forks ............................................................................. 3-69 Windscreen Washer ................................................................................ 3-71 Checking the Level .............................................................................. 3-71 Fire Extinguisher (if fitted) ........................................................................ 3-72 Checking the Fire Extinguisher ........................................................... 3-72

Section 3 - Maintenance Routine Maintenance Service Requirements 3-1 3-1 9803/9510-04 Routine Maintenance Service Requirements Introduction T3-095 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. A Service Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly. 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. Fit for Purpose Tests for Lifting Equipment T3-097 All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice. Obtaining Replacement Parts T3-096 If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor.

Section 3 - Maintenance Routine Maintenance Service Requirements 3-2 3-2 9803/9510-04 Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine (Introduction section). The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

Section 3 - Maintenance Routine Maintenance Health and Safety 3-3 3-3 9803/9510-04 Health and Safety Lubricants T3-060_2 Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too. 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, so take special care when handling used oils, which might be diluted with fuel contamination. 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, plus the following. Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers. Waste Disposal ! CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. INT-3-2-14 All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground. Handling ! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3 New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1 Avoid prolonged, excessive or repeated skin contact with used oil. 2 Apply a barrier cream to the skin before handling used oil. 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.

Section 3 - Maintenance Routine Maintenance Health and Safety 3-4 3-4 9803/9510-04 3 Avoid skin contact with oil soaked clothing. 4 Don't keep oily rags in pockets. 5 Wash dirty clothing before re-use. 6 Throw away oil-soaked shoes. First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice. Skin In the case of excessive skin contact, wash with soap and water. Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires ! WARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus. 7-3-1-3_1

Section 3 - Maintenance Routine Maintenance Health and Safety 3-5 3-5 9803/9510-04 Battery T3-061 ! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. 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 to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) 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. When reconnecting, fit the positive (+) lead first. 5-3-4-12 ! CAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14 ! WARNING 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 ! DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1_3 ! CAUTION Damaged or spent batteries and any residue from fires or spillage 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 ! WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

Section 3 - Maintenance Routine Maintenance Health and Safety 3-6 3-6 9803/9510-04 Warning Symbols The following warning symbols may be found on the battery. First Aid - Electrolyte Do the following if electrolyte: Gets into your eyes Immediately flush with water for 15 minutes, always get medical help. 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 help. Gets onto your skin Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. Symbol Meaning A289230-1 Keep away from children. A289260-1 Shield eyes. A289280 No smoking, no naked flames, no sparks. A289250 Explosive Gas. A289240 Battery acid. A289270 Note operating instructions.

JCB 3.0D 4x4 Teletruk OEM Service & Repair Manual

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