jcb JCB116 Service Manual Download Page 2

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9813/7700-3

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Summary of Contents for JCB116

Page 1: ...t studying the Operator s Manual You must understand and follow the instructions in the Operator s Manual If you do not understand anything ask your employer or JCB dealer to explain it Do not operate...

Page 2: ...9813 7700 3 Notes Find manuals at https best manuals com...

Page 3: ...B116DD VM116 EN 9813 7700 SERVICE MANUAL Volume 2 JCB116 JCB116D JCB116DD VM116 EN 9813 7700 SERVICE MANUAL Volume 3 JCB116 JCB116D JCB116DD VM116 EN 9813 7700 SERVICE MANUAL Volume 4 JCB116 JCB116D J...

Page 4: ...Notes 9813 7700 3 Find manuals at https best manuals com...

Page 5: ...ety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessment 01 11 01 03 27 Maintenance Positions 01 12 01 06 About this Manual 01 06 03 Model and Serial Number 01 1...

Page 6: ...17 09 04 Acronyms Glossary FOPS Falling Object Protective Structure HVAC Heating Ventilation Air Conditioning PIL Parts Identification List ROPS Roll Over Protective Structure Find manuals at https be...

Page 7: ...y Yours and Others 01 3 01 03 06 Safety Warnings 01 4 01 03 09 General Safety 01 5 01 03 12 Maintenance Safety 01 6 01 03 18 Operating Safety 01 8 01 03 21 Worksite Safety 01 10 01 03 24 Risk Assessme...

Page 8: ...Notes 01 2 9813 7700 3 01 2 Find manuals at https best manuals com...

Page 9: ...hazards and how to avoid them If you do not fully understand the warning messages ask your employer or JCB dealer to explain them Safety is not just a matter of responding to the warnings All the time...

Page 10: ...ion which if not avoided could result in death or serious injury The signal word CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury The signal word N...

Page 11: ...ware of medicines which can cause drowsiness Feeling Unwell Do not attempt to operate the machine if you are feeling unwell By doing so you could be a danger to yourself and those you work with Mobile...

Page 12: ...ulic Pressure Hydraulic fluid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure t...

Page 13: ...composition e g charring is found refer to the next paragraph for safety instructions Do not touch component or surrounding area Used fluoroelastomeric components subjected to temperatures greater tha...

Page 14: ...y kill you or bystanders if they are inhaled Do not operate the machine in closed spaces without making sure there is good ventilation If possible install an exhaust extractor If you begin to feel dro...

Page 15: ...Modification of the machine s configuration by the user e g the fitting of large and non approved attachments may result in a restriction of the machine visibility Hands and Feet Keep your hands and...

Page 16: ...leak is suspected contact the local gas company immediately and warn all personnel on the site Ban smoking make sure that all naked lights are extinguished and switch off any engines which may be runn...

Page 17: ...nd is there sufficient fuel to complete the job if applicable The Load How heavy is it Is it within the capabilities of the machine How bulky is it The greater the surface area the more affected it wi...

Page 18: ...nce procedure 1 Park the machine on solid level ground Figure 2 2 Install the articulation lock Refer to PIL 06 27 3 Move the drive lever to the park position 4 Stop the engine and remove the ignition...

Page 19: ...ust be correctly parked on solid level ground To prevent anyone starting the engine remove the ignition key Disconnect the battery when you are not using electrical power If you do not take these prec...

Page 20: ...01 Machine 06 About this Manual 01 14 9813 7700 3 01 14 06 About this Manual Contents Page No 01 06 03 Model and Serial Number 01 15 01 06 06 Using the Manual 01 16...

Page 21: ...r 01 15 9813 7700 3 01 15 03 Model and Serial Number Introduction This manual provides information for the following model s in the JCB machine range Model From To JCB116 2492271 2492450 JCB116D 24924...

Page 22: ...Diagnostics Information in this manual can help you diagnose machine faults Before attempting to diagnose possible faults check the following Ensure that the operator understands the machine controls...

Page 23: ...01 Machine 09 Description 01 17 9813 7700 3 01 17 09 Description Contents Page No 01 09 12 Main Component Locations 01 19 01 09 15 Service Point Locations 01 20...

Page 24: ...Notes 01 18 9813 7700 3 01 18...

Page 25: ...A B C D E F G H N K L J M N P A ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure B Engine C Exhaust D Air filter E Hydraulic pumps F Rear axle G Axle hydraulic drive motor...

Page 26: ...cations 01 20 9813 7700 3 01 20 15 Service Point Locations Introduction Machine Installed with canopy Figure 4 C B A F D E G A Coolant expansion tank B Battery isolator C Battery D Water separator E F...

Page 27: ...7700 3 01 21 Figure 5 F E A G H D C B J A Engine oil filter B Engine oil filler cap and engine oil dipstick C Fuel Filter D Air filter E Diesel fuel filler cap F Hydraulic oil filler cap G Hydraulic...

Page 28: ...9813 7700 3 01 22 Machine Installed with Cab Figure 6 C B A F D E G H J A Coolant expansion tank B Battery isolator C Battery D Water separator E Fuel filter F Hydraulic filter G Washer bottle H Prima...

Page 29: ...7700 3 01 23 Figure 7 F E A G D C B J H A Engine oil filter B Engine oil filler cap and engine oil dipstick C Fuel filter D Air filter E Diesel fuel filler cap F Hydraulic oil filler cap G Hydraulic...

Page 30: ...01 Machine 33 Cleaning 01 24 9813 7700 3 01 24 33 Cleaning Contents Page No 01 33 00 General 01 25...

Page 31: ...ender the machine inoperable Remove dirt using a brush or damp cloth Clean the product with water and or steam Do not let mud debris etc to collect on the product Before you do any service procedures...

Page 32: ...aim the water jet directly at bearings oil seals or the engine air induction system Use a low pressure water jet and brush to remove dried mud or dirt Use a pressure washer to remove soft dirt and oi...

Page 33: ...tment 06 4 06 06 06 Engine Compartment 06 5 06 06 39 Cab Canopy 06 7 06 33 Articulated Joint 06 33 00 General 06 11 06 63 Identification Label 06 63 00 General 06 17 06 63 03 Machine 06 18 06 63 06 En...

Page 34: ...9813 7700 3 2017 09 20 Acronyms Glossary FOPS Falling Object Protective Structure PIN Product Identification Number ROPS Roll Over Protective Structure...

Page 35: ...mework 06 Moveable Panel and Cover 06 1 9813 7700 3 06 1 06 Moveable Panel and Cover Contents Page No 06 06 00 General 06 3 06 06 03 Battery Compartment 06 4 06 06 06 Engine Compartment 06 5 06 06 39...

Page 36: ...Notes 06 2 9813 7700 3 06 2...

Page 37: ...duction Access panels provide easy access to the machine major components test and service points and other parts which require routine testing servicing adjusting replacement or repair Before you ope...

Page 38: ...and Cover 03 Battery Compartment 06 4 9813 7700 3 06 4 03 Battery Compartment Introduction The battery box is installed on the right side of the rear chassis Figure 8 A B D C A Battery box B Battery i...

Page 39: ...06 5 06 Engine Compartment Introduction Open 1 Make the machine safe 2 Stop the engine and remove the ignition key 3 Use the ignition key to unlock the cover 4 Use the handle to release the latch Open...

Page 40: ...d Framework 06 Moveable Panel and Cover 06 Engine Compartment 06 6 9813 7700 3 06 6 Close 1 Pull the cover down using the cable 2 Make sure the cover is closed correctly 3 Use the ignition key to lock...

Page 41: ...6 7 9813 7700 3 06 7 39 Cab Canopy Introduction Open 1 Make the machine safe Refer to PIL 01 03 2 Stop the engine and remove the ignition key 3 Use the ignition key to unlock the door 4 Use the handle...

Page 42: ...y and Framework 06 Moveable Panel and Cover 39 Cab Canopy 06 8 9813 7700 3 06 8 Close 1 Push the door to close 2 Make sure the door is closed correctly with the latch 3 Use the ignition key to lock th...

Page 43: ...06 Body and Framework 33 Articulated Joint 06 9 9813 7700 3 06 9 33 Articulated Joint Contents Page No 06 33 00 General 06 11...

Page 44: ...Notes 06 10 9813 7700 3 06 10...

Page 45: ...06 11 00 General Introduction 06 11 Check Condition 06 12 Disassemble and Assemble 06 13 Introduction The articulated joint is a flexible joint which enables two or more sections of a machine that ar...

Page 46: ...06 Body and Framework 33 Articulated Joint 00 General 06 12 9813 7700 3 06 12 Check Condition Check the articulated joint for signs of cracks or damage renew the part if necessary...

Page 47: ...e is very heavy Put a sling to support the drum frame weight when it is removed Weight Force 4 910kg 8 Remove the five bolts and washers from the top of the bearing plate 9 Install a lifting eye bolt...

Page 48: ...late D Support washer 1 E Disc spring 1 F Bearing cup 1 G Bearing cone 1 H Seal 1 J Seal 2 K Bearing cone 2 L Bearing cup 2 M Central joint N Capscrew P Bolt Q Bottom bearing pivot R Seal 3 S Bearing...

Page 49: ...value 12 Install the support washer 2 and the disc spring 2 on to the lower lug of the machine rear frame 13 Install the bearing cup 3 into the lower lug of the machine rear frame 14 Install a new se...

Page 50: ...Framework 63 Identification Label 06 16 9813 7700 3 06 16 63 Identification Label Contents Page No 06 63 00 General 06 17 06 63 03 Machine 06 18 06 63 06 Engine 06 19 06 63 15 Operator Protective Stru...

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