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Documents & Manuals

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Tensioning Guide
Belt-diagram
C-120 pulleys
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Work Order Templates

Pre-built workflows to keep your asset running smoothly.

Daily Electrical System Inspection
Replace Roller and Pulley
Install Engine B-120
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Procedures

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Motion Industries
Applied Industrial Technologies
Electrical Brothers
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Parts

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Drive Motor
B2 Rollers
Tensioning System
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JCB Telescopic Handler 507-42

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Maintenance Plans for JCB Telescopic Handler Model 507-42

Integrate maintenance plans directly into your work orders in MaintainX.

Crankcase Ventilation Filter Replacement

Make the machine safe. Refer to (PIL 01-03).

Get access to the engine. Refer to (PIL 06-06).

Rotate the filter cover anti-clockwise and remove.

Lift out the filter element and discard it.

Clean the inside of the filter housing. Remove all oil and sludge contamination.

Make sure that the oil drain in the bottom of the filter housing is not blocked with sludge.

Install a new filter element. Make sure that the correct type of filter element is installed.

Align the arrows on both parts to install the filter cover.

Sign off on the filter replacement

Run this procedure

Tensioner Replacement

Before Removal

Machine made safe

Engine safe to work on

Access to engine obtained

Drive belt removed

Remove

Tensioner assembly bolts removed

Tensioner pulley lifted from cylinder block

Install

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Air Filter Check

The air filter element (s) should be changed at the recommended service interval, refer to the Maintenance Schedules. Refer to: PIL 78-24.

Check all the hose connections for loose installations and damaged hose clamps

Look specifically for splits or cracks in the hoses

Pay particular attention to the connections on the air intake to turbo compressor and on the crossover tube

Renew any damaged components

In addition, most air filter housings will be installed with a vacuum switch. The switch will detect if there is a restriction on the air intake, and activate warning indicators such as an audible alarm and/or a visual indicator.

Is the vacuum switch working properly?

Sign off on the air filter check

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Oil Level Check

Warning: Failure to replace the oil and filter at the recommended interval could cause serious engine failure.

Machine made safe as per PIL 01-03

Access to the engine obtained

Oil level is between the two marks on the dipstick

Is it necessary to add oil?

If necessary, add recommended oil through one of the filler points.

Sign off on the oil level check

Run this procedure

Special Tools Replacement

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.

CAUTION! Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.

1. Place a container of suitable size beneath the drain plug.

2. Remove the oil sump drain plug and 'O' ring. Let the oil drain out, then clean and install the drain plug with a new 'O' ring. Tighten the plug to the correct torque value.

3. Loosen and remove the filter housing drain plug. Let the oil fully drain. Install the plug. Tighten the plug to the correct torque value.

4. Unscrew the filter canister, use special tool if necessary.

Special Tool: Oil Filter Removal Tool (Qty.: 1)

5. Clean the seal face of the filter head.

6. Smear the seal on the new filter canister with clean engine oil.

Run this procedure