jcb JCB116 Service Manual

jcb JCB116 Service Manual

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SERVICE MANUAL
ROLLER
JCB116, JCB116D, JCB116DD, VM116
EN - 9813/7700 - ISSUE 3 - 09/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © 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.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first 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 the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
06 - Body and Framework
09 - Operator Station
12
-
Heating,
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
Ventilating
and
Air-

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Summary of Contents for jcb JCB116

  • Page 1 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. SERVICE MANUAL Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
  • Page 2 Notes: 9813/7700-3 Find manuals at https://best-manuals.com...
  • Page 3 Spine Cards SERVICE MANUAL SERVICE MANUAL Volume 1 Volume 2 JCB116, JCB116D, JCB116, JCB116D, JCB116DD, VM116 JCB116DD, VM116 EN 9813/7700 EN 9813/7700 SERVICE MANUAL SERVICE MANUAL Volume 3 Volume 4 JCB116, JCB116D, JCB116, JCB116D, JCB116DD, VM116 JCB116DD, VM116 EN 9813/7700...
  • Page 4 Notes: 9813/7700-3 Find manuals at https://best-manuals.com...
  • Page 5: Table Of Contents

    01 - Machine Contents Page No. Acronyms Glossary ............................ 01-2 01-03 Safety 01-03-03 Safety - 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 ......................
  • Page 6: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure HVAC Heating Ventilation Air Conditioning Parts Identification List ROPS Roll-Over Protective Structure 9813/7700-3 2017-09-04 Find manuals at https://best-manuals.com...
  • Page 7 01 - Machine 03 - Safety 03 - Safety Contents Page No. 01-03-03 Safety - 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 ......................
  • Page 8 Notes: 01 - 2 9813/7700-3 01 - 2 Find manuals at https://best-manuals.com...
  • Page 9: Safety

    They inform you of potential 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.
  • Page 10: Safety Warnings

    01 - Machine 03 - Safety 06 - Safety Warnings 06 - Safety Warnings Introduction In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 11: General Safety

    Keep long hair restrained. Remove altered in any way which could affect or invalidate its rings, watches and personal jewellery. compliance. For advice consult your JCB dealer. Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs.
  • Page 12: Maintenance Safety

    Repairs pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may If your machine does not function correctly in cause serious injury or death.
  • Page 13 Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such Viton®, FluorelTM Technoflon®.
  • Page 14: Operating Safety

    Before doing any job not covered in this manual, find Parking out the correct procedure. Your local JCB distributor will be glad to advise you. An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Fuel Manual to park the machine correctly.
  • Page 15 01 - Machine 03 - Safety 18 - Operating Safety Electrical Power Cables Hands and Feet You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. the machine or its attachments too close to electrical When using the machine, keep your hands and feet power cables.
  • Page 16: Worksite Safety

    01 - Machine 03 - Safety 21 - Worksite Safety 21 - Worksite Safety An applicable worksite organisation is required in order to minimise hazards that are caused by restricted visibility. The worksite organisation is a Introduction collection of rules and procedures that coordinates the machines and people that work together in WARNING You or others can be killed or seriously the same area.
  • Page 17: Risk Assessment

    If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be a specific task, contact your JCB dealer who will be in or to enter the area while operations are in pleased to advise you.
  • Page 18: Maintenance Positions

    01 - Machine 03 - Safety 27 - Maintenance Positions 27 - Maintenance Positions Introduction Introduction ............ 01-12 Make the machine safe before you start a Health and Safety .......... 01-13 maintenance procedure. 1. Park the machine on solid, level ground. Figure 2.
  • Page 19 01 - Machine 03 - Safety 27 - Maintenance Positions Health and Safety WARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.
  • Page 20: About This Manual

    01 - Machine 06 - About this Manual 06 - About this Manual Contents Page No. 01-06-03 Model and Serial Number ....................01-15 01-06-06 Using the Manual ......................01-16 01 - 14 9813/7700-3 01 - 14...
  • Page 21: Model And Serial Number

    01 - Machine 06 - About this Manual 03 - Model and Serial Number 03 - Model and Serial Number Introduction This manual provides information for the following model(s) in the JCB machine range: Model From: JCB116 2492271 2492450 JCB116D...
  • Page 22: Using The Manual

    06 - Using the Manual Introduction Information in this manual conforms to a standard List). These headings are assigned numerical JCB service manual format. The format uses section identification references. headings taken from a PIL (Parts Identification Table 1. Example...
  • Page 23: Description

    01 - Machine 09 - Description 09 - Description Contents Page No. 01-09-12 Main Component Locations ................... 01-19 01-09-15 Service Point Locations ....................01-20 01 - 17 9813/7700-3 01 - 17...
  • Page 24 Notes: 01 - 18 9813/7700-3 01 - 18...
  • Page 25: Main Component Locations

    01 - Machine 09 - Description 12 - Main Component Locations 12 - Main Component Locations Introduction Figure 3. A ROPS (Roll-Over Protective Structure)/ FOPS B Engine (Falling Object Protective Structure) C Exhaust D Air filter E Hydraulic pumps F Rear axle G Axle hydraulic drive motor H Articulation joint J Scraper...
  • Page 26: Service Point Locations

    01 - Machine 09 - Description 15 - Service Point Locations 15 - Service Point Locations Introduction Machine Installed with canopy Figure 4. A Coolant expansion tank B Battery isolator C Battery D Water separator E Fuel filter F Hydraulic filter G Primary fuse 01 - 20 9813/7700-3...
  • Page 27 01 - Machine 09 - Description 15 - Service Point Locations Figure 5. 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 oil level indicator H Toolbox location J Fuel lubricity filter...
  • Page 28 01 - Machine 09 - Description 15 - Service Point Locations Machine Installed with Cab Figure 6. A Coolant expansion tank B Battery isolator C Battery D Water separator E Fuel filter F Hydraulic filter G Washer bottle H Primary fuse J HVAC (Heating Ventilation Air Conditioning) filter 01 - 22...
  • Page 29 01 - Machine 09 - Description 15 - Service Point Locations Figure 7. 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 oil level indicator H Toolbox location J Fuel lubricity filter...
  • Page 30 01 - Machine 33 - Cleaning 33 - Cleaning Contents Page No. 01-33-00 General ........................... 01-25 01 - 24 9813/7700-3 01 - 24...
  • Page 31 01 - Machine 33 - Cleaning 00 - General 00 - General Introduction WARNING When using cleaning agents, solvents Introduction ............ 01-25 or other chemicals, you must adhere to Preparation ............ 01-26 the manufacturer's instructions and safety precautions. CAUTION To avoid burning, wear personal protective equipment when...
  • Page 32 01 - Machine 33 - Cleaning 00 - General Preparation Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine 1. Make the machine safe. Stop the machine and is to be washed using a high pressure system.
  • Page 33 06 - Body and Framework Contents Page No. Acronyms Glossary ............................ 06-2 06-06 Moveable Panel and Cover 06-06-00 General ..........................06-3 06-06-03 Battery Compartment ....................... 06-4 06-06-06 Engine Compartment ....................... 06-5 06-06-39 Cab/Canopy ........................06-7 06-33 Articulated Joint 06-33-00 General ...........................
  • Page 34: Acronyms Glossary

    Acronyms Glossary FOPS Falling Object Protective Structure Product Identification Number ROPS Roll-Over Protective Structure 9813/7700-3 2017-09-20...
  • Page 35 06 - Body and Framework 06 - Moveable Panel and Cover 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 Cab/Canopy ........................06-7 06 - 1 9813/7700-3 06 - 1...
  • Page 36 Notes: 06 - 2 9813/7700-3 06 - 2...
  • Page 37: Moveable Panel And Cover

    06 - Body and Framework 06 - Moveable Panel and Cover 00 - General 00 - General Introduction 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.
  • Page 38: Battery Compartment

    06 - Body and Framework 06 - Moveable Panel and Cover 03 - Battery Compartment 03 - Battery Compartment Introduction The battery box is installed on the right side of the rear chassis. Figure 8. A Battery box B Battery isolator switch C Battery D Rear chassis 06 - 4...
  • Page 39: Engine Compartment

    06 - Body and Framework 06 - Moveable Panel and Cover 06 - Engine Compartment 06 - Engine Compartment Introduction Open 3. Use the ignition key to unlock the cover. 4. Use the handle to release the latch. Open the 1.
  • Page 40 06 - Body and Framework 06 - Moveable Panel and Cover 06 - Engine Compartment Close 1. Pull the cover down using the cable. 2. Make sure the cover is closed correctly. 3. Use the ignition key to lock the cover. 06 - 6 9813/7700-3 06 - 6...
  • Page 41: Cab/Canopy

    06 - Body and Framework 06 - Moveable Panel and Cover 39 - Cab/Canopy 39 - Cab/Canopy Introduction Open 3. Use the ignition key to unlock the door. 4. Use the handle to release the catch. Open the 1. Make the machine safe. door.
  • Page 42 06 - Body and Framework 06 - Moveable Panel and Cover 39 - Cab/Canopy 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 the door. 06 - 8 9813/7700-3 06 - 8...
  • Page 43 06 - Body and Framework 33 - Articulated Joint 33 - Articulated Joint Contents Page No. 06-33-00 General ........................... 06-11 06 - 9 9813/7700-3 06 - 9...
  • Page 44 Notes: 06 - 10 9813/7700-3 06 - 10...
  • Page 45 06 - Body and Framework 33 - Articulated Joint 00 - General 00 - General Introduction Introduction ............ 06-11 The articulated joint is a flexible joint which enables Check (Condition) .......... 06-12 two or more sections of a machine that are linked together to allow for greater capacity, flexibility of Disassemble and Assemble ......
  • Page 46 06 - Body and Framework 33 - Articulated Joint 00 - General Check (Condition) Check the articulated joint for signs of cracks or damage, renew the part if necessary. 06 - 12 9813/7700-3 06 - 12...
  • Page 47 06 - Body and Framework 33 - Articulated Joint 00 - General Disassemble and Assemble Raised Machine 10. Remove the remaining five bolts and washers from the bottom of the bearing plate. Never position yourself or any part of your body under a raised machine which is not correctly 11.
  • Page 48 06 - Body and Framework 33 - Articulated Joint 00 - General Figure 11. Bolt Washer Bearing plate Support washer 1 Disc spring 1 Bearing cup 1 Bearing cone 1 Seal 1 Seal 2 Bearing cone 2 Bearing cup 2 Central joint Capscrew Bolt...
  • Page 49 06 - Body and Framework 33 - Articulated Joint 00 - General Assemble 20. Install the new seals 1 and 2 onto the drum frame lugs. The bearings in the steering articulation joints are 21. Install the new bearing cones 1 and 2 on the drum designed to be assembled without grease or other frame lugs.
  • Page 50 06 - Body and Framework 63 - Identification Label 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 Structure ..................06-21 06 - 16 9813/7700-3 06 - 16...
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