Page 1 Body & Framework Service Manual Electrics Controls ROBOT 150, 165 Hydraulics Transmission PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT Brakes OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, STAFFORDSHIRE, ST14 5PA, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Engine Publication No. 9803/8500...
Page 3 Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.
Page 4: Table Of Contents
General Information Section 1 Section 1 Contents Page No. Identifying your Machine 1 - 1 Torque Settings 2 - 1 Service Tools - Numerical List 3 - 1 - Electrics 4 - 1 - Hydraulics 4 - 2 Sealing and Retaining Compounds 5 - 1 9803/8500 Issue 1...
Page 5 Identifying your Machine 1 - 1 The serial number of the chassis, engine, lift arm and hydraulic pump unit positively identify the type of JCB Skid Steer Loader you have. Machine Identification Plate The machine identification plate A is located as shown. It is stamped with the serial numbers of the major individual units.
Page 6: Identifying Your Machine
Unit Identification The engine serial number on XUD engines is stamped on a machined area B on the top of the cylinder block. On JCB Diesel engines the number is stamped on a label G on the left side of the cylinder block.
Page 7: Torque Settings
(10) (12) (16) (20) (24) (30) 1633 1205 (36) 2854 2105 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. 9803/8500 Issue 2*...
Page 8: Service Tools
892/00923 A.R.V Test Block - Commercial Hyd. 4 - 3 4104/0253 Activator (Bottle) 5 - 1 992/09300 Spanner 4 - 3 4104/1557 JCB Cleaner/Degreaser 5 - 1 992/09400 Spanner 4 - 3 816/00189 Blanking Cap 4 - 4 992/09500 Spanner...
Page 9: Electrics
General Information Section 1 Section 1 4 - 1 Service Tools 4 - 1 Section C - Electrics AVO Test Kit 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature Probe 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 188230...
Page 10: Hydraulics
General Information Section 1 Section 1 4 - 2 Service Tools 4 - 2 Section E - Hydraulics Hydraulic Circuit Pressure Test Kit 892/00253 Pressure Test Kit 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in 892/00254...
Page 11 General Information Section 1 Section 1 4 - 3 Service Tools 4 - 3 Section E - Hydraulics 220840 A215880 S270650 892/00858 Pump support bracket - for engine removal. 892/00252 Test Block for A. R. V. - Husco valves 892/00923 Test Block for A. R. V. - Commercial Hydraulic valves 193850 188140...
Page 12 General Information Section 1 Section 1 4 - 4 Service Tools 4 - 4 Section E - Hydraulics 193880 193870 Male Cone Blanking Plug Female Cone Blanking Plug 816/00294 1/4 in BSP 892/00055 1/4 in BSP 816/00189 3/8 in BSP 892/00056 3/8 in BSP 816/00190...
Page 13: Sealing And Retaining Compounds
4104/1557 Aerosol The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E). The list above has been changed accordingly. References to these products on subsequent pages in this service manual will be progressively updated but for convenience a cross reference table is shown below.
Page 14 Care and Safety Section 2 Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 Safety Decals 5 - 1 9803/8500 Issue 1...
Page 15 Care and Safety Section 2 Section 2 1 - 1 1 - 1 Safety Notices In this publication and on the machine there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. ! DANGER Denotes an extreme hazard exists.
Page 16 2 - 1 All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
Page 17 Do not try to upgrade the machine Passengers in or on the machine can cause accidents. The performance with unapproved modifications. JCB Skid Steer Loader is a one man machine. Do not carry INT-2-1-4 passengers. INT-2-2-2...
Page 18 Care and Safety Section 2 Section 2 4 - 1 4 - 1 Maintenance Safety ! WARNING ! WARNING Repairs Battery Gases Do not try to do repairs or any other type of maintenance Batteries give off explosive gases. Keep flames and sparks work you do not understand.
Page 19 Care and Safety Section 2 Section 2 4 - 2 4 - 2 Maintenance Safety (cont'd) ! WARNING ! CAUTION Rams Oil is toxic. If you swallow any oil, do not induce vomiting, The efficiency of the rams will be affected if they are not kept seek medical advice.
Page 20 The decals and their attachment points are shown on the following pages. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. INT-3-3-3 ! WARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals.
Page 21 Care and Safety Section 2 Section 2 5 - 2 5 - 2 Safety Decals (cont'd) 9803/8500 Issue 2...
Page 22 Routine Maintenance Section 3 Section 3 Contents Page No. Fluids, Capacities and Lubricants 1 - 1 Lubricants Health and Safety 1 - 2 Fuel System 2 - 1 Service Schedules 3 - 1 Loader Arm Safety Strut 4 - 1 Greasing 5 - 1 Body and Framework...
Page 23 Changing the Oil and Filter - Peugeot engine 10 - 2 Checking the Oil Level - JCB Diesel engine 10 - 4 Changing the Oil and Filter - JCB Diesel engine 10 - 4 Draining the Fuel Filter - Peugeot engine 10 - 6...
Page 24: Fluids, Capacities And Lubricants
(see Coolant Mixtures) Fuel System 60 litres Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D Grease Points JCB Special HP Grease or Lithium based, No. 2 consistency JCB Special MPL Grease Chain Case Fill to level plug Engine Oil...
Page 25: Health And Safety
Lubricants - Health and Safety Hygiene Note the following when removing engine oil from skin: JCB lubricants are not a health risk when used properly for a Wash your skin thoroughly with soap and water. their intended purposes. b Using a nail brush will help.
Page 26: Fuel System
The recommended fuel temperatures below 0 °C (32 °F). These fuels have a lower specification for JCB engines is given below. viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel Cetane Number: 45 (minimum) flowing through the filter).
Page 27: Service Schedules
Engine oil and filter Tightness of wheel bolts Hydraulic fluid filter Fuel filter - drain if necessary (JCB Diesel engine only) EVERY 10 OPERATING HOURS OR DAILY Note: The engine is supplied with "Running in" oil. This must whichever occurs first be changed together with engine oil filter after the first 50 operating hours.
Page 28 Do the Daily to 500 hour jobs plus: Check (Engine Stopped) Air cleaner dust valve Radiator matrix Tighten cylinder head bolts (JCB Diesel engine only) Hydraulic tank breather Engine cam belt - condition (Peugeot engine only) Check (Engine stopped) Drive chain tension...
Page 29: Loader Arm Safety Strut
Routine Maintenance Section 3 Section 3 4 - 1 4 - 1 Loader Arm Safety Strut Installing Removing ! WARNING ! WARNING Raised loader arms can drop suddenly and cause You could be killed or injured if the loader control is serious injury.
Page 30: Greasing
Routine Maintenance Section 3 Section 3 5 - 1 5 - 1 Greasing The machine must be greased regularly to keep it working efficiently. Regular greasing will also increase the machine's working life. Grease should be applied with a grease gun, normally two strokes of the gun should be sufficient.
Page 31 Routine Maintenance Section 3 Section 3 5 - 2 5 - 2 Greasing (cont'd) Loader Arm Pivot Points - for interval see Service Schedule Lift and Compensating Ram Pivots - for interval see Service Schedule Total of 2 grease points Total of 4 grease points ! WARNING Raised loader arms can drop suddenly and cause...
Page 32: Body And Framework
Routine Maintenance Section 3 Section 3 6 - 1 6 - 1 Body and Framework Oiling - for interval see Service Schedule The following points should be lightly lubricated with engine oil. Engine Compartment Rear Door Latch Switch off the engine and ensure it cannot be started while you are doing this job.
Page 33: Oiling
Routine Maintenance Section 3 Section 3 6 - 2 6 - 2 Body and Framework (cont’d) Oiling (cont’d) - for interval see Service Schedule Control Linkages - Manual Controls up to machine number 677999 Switch off the engine and ensure it cannot be started while you are doing this job.
Page 34 Routine Maintenance Section 3 Section 3 6 - 3 6 - 3 Body and Framework (cont’d) Oiling (cont’d) - for interval see Service Schedule Control Linkages - Manual Controls from machine number 678000 Switch off the engine and ensure it cannot be started while you are doing this job.
Page 35: Cleaning Cab Interior
Routine Maintenance Section 3 Section 3 6 - 4 6 - 4 Body and Framework (cont'd) Cleaning Cab Interior - for interval see Service Schedule Because the machine body base is of solid steel construction special provision is made for cleaning out the cab. The cab floor profile incorporates two gutters, one on each side.
Page 36: Electrical System
Routine Maintenance Section 3 Section 3 7 - 1 7 - 1 Electrical System Battery Safety ! 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.
Page 37: Checking The Electrolyte Level
Routine Maintenance Section 3 Section 3 7 - 2 7 - 2 Electrical System (cont'd) Checking the Electrolyte Level - for interval see Service Schedule The battery is mounted in a compartment above the diesel fuel tank. Stop the engine. Unlatch and remove the battery cover A.
Page 38: Changing The Light Bulbs
Routine Maintenance Section 3 Section 3 7 - 3 7 - 3 Electrics (cont'd) Changing the Light Bulbs Worklight Bulb Support the light unit B remove screws A. Lift and turn light unit B to gain access to connectors C and D.
Page 39 Routine Maintenance Section 3 Section 3 7 - 4 7 - 4 Electrics (cont'd) Changing the Light Bulbs (cont'd) Switches and Warning Lights With a fine screwdriver ease the Switch/Warning Lights A from their sockets in the control panel. The bulb holders B can then be pulled from the back of the Switch/Warning Lights and the bulbs will come with them.
Page 40: Hydraulic System
Routine Maintenance Section 3 Section 3 8 - 1 8 - 1 Hydraulic System ! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks.
Page 41: Transmission
Routine Maintenance Section 3 Section 3 9 - 1 9 - 1 Transmission Drive Chain Lubrication Changing the Oil - for interval see Service Schedule The final drive to the wheels is by chains. A chain casing on Park the machine on level ground. each side of the machine houses two chains, one to the front wheel and one to the rear wheel.
Page 42: Drive Chain Lubrication From Machine Number 678000
Clean bolt A, its spring washer and its hole and apply A hole until the oil is level with the bottom of the hole. JCB Threadlocker & Sealer to the threads of the bolt. Do Wipe up any oil spillage.
Page 43: Adjusting The Drive Chain Tension
Routine Maintenance Section 3 Section 3 9 - 3 9 - 3 Transmission (cont'd) Adjusting the Drive Chain Tension Note: The drive chains on machines after serial no. 676702 Remove the rear wheel. are pre-tensioned during manufacture and there is no provision for routine adjustment in service.
Page 44: Tyres And Wheels
3-3-2-1 Tyre Table Robot 150 Robot 165 Robot 150 & 165 Pneumatic Tyres - size 27 x 8.5 x 15 10 x 16.5 700 x R15 XZM 4.1 (60) 3.1 (45)
Page 45 Routine Maintenance Section 3 Section 3 10 - 1 10 - 1 Engine Air Filter up to machine number 677999 Changing the Elements - for interval see Service Schedule Clean inside canister E, and dust valve F. ! CAUTION Carefully insert the new elements into the canister. Make sure they seat correctly by smearing the seals G and H The outer element must be renewed immediately if the with grease and checking for a witness mark on the...
Page 46 Routine Maintenance Section 3 Section 3 10 - 1A 10 - 1A Engine Depress clips A and lift off cover B. Remove outer element C. Take care not to tap or knock the element. If Air Filter from machine number 678000 the inner element is to be changed, lift up pulls D and remove inner element E.
Page 47 Routine Maintenance Section 3 Section 3 10 - 2 10 - 2 Engine (cont'd) Checking the Oil Level - Peugeot XUD engine - for interval see Service Schedule ! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
Page 48 Routine Maintenance Section 3 Section 3 10 - 3 10 - 3 Engine (cont'd) Changing the Oil and Filter - Peugeot engine (cont'd) After emptying the sump, unscrew drain coupling E and replace the dust cap D. Note: The valve closes automatically as the coupling is removed.
Page 49 Make sure the filler cap and the dipstick are secure. Close and secure the engine compartment hinged top cover and rear door. Changing the Oil and Filter - JCB Diesel engine - for interval see Service Schedule S255840 ! WARNING Hot oil and engine components can burn you.
Page 50 10 - 5 10 - 5 Engine (cont'd) Changing the Oil and Filter - JCB Diesel engine (cont'd) Unscrew the filter canister E, using a chain wrench if necessary. Remember that it will contain some oil. Clean filter head F.
Page 51 Routine Maintenance Section 3 Section 3 10 - 6 10 - 6 Engine (cont'd) Draining the Fuel Filter - Peugeot engine machines - for interval see Service Schedule The fuel filter is located on the rear left hand side of the chassis.
Page 52 Section 3 10 - 7 10 - 7 Engine (cont'd) Draining the Fuel Filter - JCB Diesel engine machines - for interval see Service Schedule The fuel filter is located on the rear left side of the chassis. Stop the engine.
Page 53 - 37 °C (- 35 °F) If necessary top up the system to the level indicated inside the expansion/filler bottle. On Perkins engine machines use JCB Universal Antifreeze. Refit the filler cap and make sure it is tight. Solution Maintains circulation...
Page 54 On JCB Diesel engines, unscrew the cylinder block drain tap C. Flush the system by pouring clean water into filler cap A. Clean and refit bottom hose B. On JCB Diesel engines, tighten the cylinder block drain tap C. 174331...
Page 55 Check the alternator belt tension which should be as follows: Peugeot engine - 10 mm (3/8 in) slack at point X. JCB Diesel engine - 7 mm (0.28 in) slack at point X. If the belt requires adjusting proceed as below Adjusting the Alternator Belt.
Page 56 Routine Maintenance Section 3 Section 3 11 - 1 11 - 1 Windscreen Washer Fill the windscreen washer bottle A with a suitable liquid. The liquid should contain a de-icing fluid to prevent it freezing. Do not use engine coolant antifreeze. 174450 9803/8500 Issue 1...
Page 57 Optional Attachments Section A Section A Contents Page No. Quick Release Couplings 1 - 1 Connecting/Disconnecting Hoses 2 - 1 Shovels 3 - 1 General Purpose and Light Duty Shovels 3 - 1 6-in-1 Shovels 3 - 1 Pallet Forks 4 - 1 Manure/Silage Fork with Top Grab 5 - 1...
Page 58: Quick Release Couplings
Optional Attachments Section A Section A 1 - 1 Quick Release Couplings 1 - 1 Flat face quick release couplings allow the operator to It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to remove and install attachments swiftly and efficiently.
Page 59 Optional Attachments Section A Section A 2 - 1 Connecting/Disconnecting Hydraulic Hoses 2 - 1 Some attachments are hydraulically powered. The following paragraphs describe how to connect and disconnect the Carry out steps 1 and 2 of connecting the hoses. hydraulic hoses safely.
Page 60: Shovels
Optional Attachments Section A Section A 3 - 1 Shovels 3 - 1 General Purpose and Light Duty Shovels Daily Maintenance Clean with the rest of the machine (if fitted). Ensure that the Quickhitch framework is not damaged or badly worn. Repair if necessary. Check for damage.
Page 61: Pallet Forks
Optional Attachments Section A Section A 4 - 1 Pallet Forks 4 - 1 The pallet fork frame includes a Rating Plate which gives its weight and its Safe Working Load. The forks should always be used in pairs as supplied. Each fork is stamped with its Part Number and Safe Working Load.
Page 62: Manure/Silage Fork With Top Grab
Optional Attachments Section A Section A 5 - 1 Manure/Silage Fork with Top Grab 5 - 1 The Manure/Silage fork is fitted with a top grab as standard. This gives extra security to the load while moving the machine. The grab is opened and closed by a hydraulic ram mounted on the fork frame.
Page 63: Attachment Frame
Optional Attachments Section A Section A 6 - 1 Attachment Frame 6 - 1 Some attachments, e.g. the Hammermaster, Earth Drill and Compactor, utilise an attachment frame for installation on a Skid Steer Loader. Daily Maintenance Clean with the rest of the machine. Check for damage.
Page 64: Technical Data
Attachments Section A Section A 7 - 1 Backhoe 7 - 1 Technical Data Main Relief Valve (MRV) 172 bar (2494 lbf/in Auxiliary Relief Valves Boom raise and lower 180 bar (2610 lbf/in Dipper raise and lower 180 bar (2610 lbf/in Slew left and right 158 bar (2291 lbf/in Bucket crowd...
Page 65: Circuit Description
Attachments Section A Section A 7 - 2 Backhoe 7 - 2 Circuit Description Neutral Circuit Relief Valves and Non-return Valves Oil from the Skid Steer Robot's hydraulic circuit enters the Main relief valve G dumps excess oil to tank via the exhaust backhoe circuit at X.
Page 66 Attachments Section A Section A 7 - 3 Backhoe 7 - 3 Valve Block The following procedures should be carried out with the backhoe removed from the Robot Skid Steer machine. Removal and Replacement Remove the two control lever knobs A by gently tapping upwards.
Page 67 Attachments Section A Section A 7 - 4 Backhoe 7 - 4 Valve Block Dismantling and Assembly S213030 9803/8500 Issue 1...
Page 68 Attachments Section A Section A 7 - 5 Backhoe 7 - 5 Valve Block General The valve block consists of a number of segments A sandwiched between end sections B and C, all held together by three studs D and nuts E. The standard block has six segments as shown in the plan view opposite.
Page 69: Pressure Testing
Attachments Section A Section A 7 - 6 Backhoe 7 - 6 Pressure Testing Slew ARV Preparing for Testing Slew the superstructure left to the end of its travel and Switch off the engine and relieve system pressure by continue to operate the lever. operating the backhoe controls a few times.
Page 70: Carriage Clamp Mechanism
Attachments Section A Section A 7 - 7 Backhoe 7 - 7 Carriage Clamp Mechanism There are four clamping devices. The following procedures apply to each device individually. Dismantling If the backhoe is still mounted on the Robot Skid Steer, release the carriage clamps by means of the carriage clamp lever (see the Backhoe Operator Handbook).
Page 71: Stabilisers
Attachments Section A Section A 7 - 8 Backhoe 7 - 8 Stabilisers The following procedures are best carried out with the backhoe mounted on the Robot Skid Steer machine. If this is not possible it will be necessary to provide an alternative means of raising the backhoe mainframe to permit removal of foot 3 and leg 5.
Page 72 Attachments Section A Section A 7 - 9 Backhoe 7 - 9 Dipper and Boom Removal and Replacement 9803/8500 Issue 1...
Page 73 Attachments Section A Section A 7 - 10 Backhoe 7 - 10 Dipper and Boom Removal and Replacement Clean round the hydraulic fittings and then disconnect the hoses from the boom ram pipework. Cap the pipes Note: When preparing to carry out the following tasks, the and hoses to prevent the ingress of dirt and moisture.
Page 74 Attachments Section A Section A 7 - 11 Backhoe 7 - 11 Rams 1218 9803/8500 Issue 1...
Page 75 Attachments Section A Section A 7 - 12 Backhoe 7 - 12 Rams Always use lifting equipment to manoeuvre the rams when Support the ram with suitable lifting equipment. Remove carrying out any of the tasks detailed here. the two roll pins G followed by pivot pins H and J in ! WARNING turn.
Page 76 Attachments Section A Section A 7 - 13 Backhoe 7 - 13 Rams (cont'd) Dismantling The numerical sequence shown in the illustration is a guide to the dismantling procedure. Note: It may be necessary to apply air or hydraulic pressure to the head side of the ram in order to extract the piston rod assembly from the cylinder.
Page 77 Attachments Section A Section A 7 - ? Backhoe 7 - ? 9803/8500 Issue 1...
Page 78 Section B Body and Framework Section B Contents Page No. Seat and Floor Plate Seat Removal and Replacement 1 - 1 Floor Plate Removal and Replacement 1 - 1 Glazing Front Window Removal and Replacement 3 - 1 Rear window Removal and Replacement 3 - 2 Side Window Removal and Replacment 3 - 4...
Page 79 Section B Body and Framework Section B 1 - 1 Seat and Floor Plate 1 - 1 Seat Removal It may be necessary to remove the operator's seat to gain access to the hydraulic pumps, motors, valves and pipework. Tilt the hydraulic controls safety restraint bar forwards. Tilt the seat 1 forwards.
Page 80 Section B Body and Framework Section B 3 - 1 Glazing 3 - 1 Front Window Removal ! CAUTION The front screen is heavy. Removal and refitting of the front screen should be done by two people, one on either side of the machine. 3-1-2-4 Stop the engine Remove the windscreen wiper blade...
Page 81 Section B Body and Framework Section B 3 - 2 Glazing 3 - 2 Rear Window 137770 9803/8500 Issue 1...
Page 82 Section B Body and Framework Section B 3 - 3 Glazing 3 - 3 Rear Window Removal The rear window is fitted with a safety device to allow escape in emergencies. Pullng ring A extracts rubber seal B from the window frame, allowing the window to be pushed out.
Page 83 Section B Body and Framework Section B 3 - 4 Glazing 3 - 4 Side Windows 136161 9803/8500 Issue 1...
Page 84 Section B Body and Framework Section B 3 - 5 Glazing 3 - 5 Side Windows Removal Wear safety glasses during this operation, to protect your eyes from any splinters of glass. Prise the window from its rubber seal using Special Tool 992/01100 or a blunt screwdriver.
Page 85 Section B Body and Framework Section B 4 - 1 Door 4 - 1 The cab door is located on the left hand side of the machine. Removal Remove one end of the door's gas strut. Open the door fully and lift from the hinges. Replacement Replacement is a reversal of the removal procedure.
Page 86 Section B Body and Framework Section B 5 - 1 Loader Arm 5 - 1 167760 9803/8500 Issue 1...
Page 87 Replacement Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL grease. Shims are available in two thicknesses (2 mm and 3 mm) and should be fitted as required on the left hand side of the loader arm pivot to eliminate end float.
Page 88 Electrics Section C Section C Contents Page No. Technical Data 1 - 1 Light Bulbs 1 - 1 Circuit Protection 1 - 2 Test Methods How to Use a Multimeter 2 - 1 How to Measure Voltage 2 - 2 How to Measure Resistance 2 - 2 How to Measure Continuity...
Page 89: Technical Data
420 to 585 according to battery type Reserve capacity (minutes) for 25 Amp load 170 to 230 Alternator Peugeot Engines 65 Amp maximum output JCB Diesel Engines 55 Amp maximum output Light Bulbs 55W (Halogen) Working Lights Indicator Lights Interior Light 1.2W...
Page 90: Circuit Protection
Electrics Section C Section C 1 - 2 Technical Data 1 - 2 Circuit Protection Fuses - early machines Relays - early machines The electrical circuits are protected by fuses. The fuses are Indicator Flasher Unit located towards the rear of the switch/warning indicator panel Door Open/Close Switch as shown in the illustration.
Page 91 Alarm Buzzer Auxiliary Isolation Relay (Black relay) Glow Plug Relay B The Glow Plug Relay for JCB Diesel engines is visually different but in the same location. 201900 Note: Depending on the number of options specified, the machine may be fitted with either one fuse board X or both fuse boards X and Y.
Page 92: Test Methods
Electrics Section C Section C 2 - 1 Test Methods 2 - 1 How to Use a Multimeter These instructions are intended to cover the use of the recommended AVO 2003 and a moving pointer (analogue) meter. Make sure that the test leads are plugged into the correct sockets. The black probe should be plugged into the black socket (sometimes, this socket is also marked by a "-", or "E"...
Page 93: How To Measure Voltage
Electrics Section C Section C 2 - 2 Test Methods 2 - 2 How to Measure Voltage (VOLTS) On the AVO 2003 Move the right slider switch to position A, and the left hand slider to the appropriate range. On an analogue meter Turn the dial to the appropriate DC Volts range.
Page 94: Testing - Specific Gravity
Electrics Section C Section C 3 - 1 Battery 3 - 1 Testing - Specific Gravity The specific gravity of the electrolyte gives an idea of the Readings should be as tabulated and should not vary state of charge of the battery. Readings should be taken between cells by more than 0.04.
Page 95: General Description
Electrics Section C Section C 4 - 1 Alternator 4 - 1 General Description Check 1 The alternator is a three phase generator having a rotating field winding and static power windings. With start switch 'ON' try the heater motor and screen wiper. When the start switch is turned on, current from the battery flows by way of the 'No Charge' warning light to the field If they operate normally, check the warning light bulb for...
Page 96: Alternator Charging Test
Electrics Section C Section C 4 - 2 Alternator 4 - 2 Alternator Charging Test If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with the ESOS fuse removed.
Page 97 Electrics Section C Section C 4 - 3 Alternator 4 - 3 S213570 9803/8500 Issue 1...
Page 98 4 - 4 Alternator 4 - 4 Removal and Replacement Dismantling and Assembling JCB Diesel Engines Dismantling Disconnect the battery negative lead. Remove suppressor 2 (if fitted) by removing nut 1 and disconnecting lead E from terminal F. Disconnect the wiring from the rear of the alternator.
Page 99: Starter Motor
Electrics Section C Section C 5 - 1 Starter Motor 5 - 1 Starting Circuit Test Before carrying out the voltmeter tests, check the battery If the reading is less than specified, connect the voltmeter condition and ensure that all connections are clean and tight. between the neutral start relay terminal D and earth.
Page 100: Removal And Replacement
Peugeot Engines JCB Diesel Engines Disconnect the battery negative lead. See Engine Workshop Manual (JCB part no. 9806/2100) for Removal, Replacement and Servicing procedures. Disconnect the cables to the main terminal A and solenoid terminal B. Unscrew securing bolts C (3 off) and withdraw the starter.
Page 101: Circuit Diagrams
Electrics Section C Section C 6 - 1 Circuit Diagram 6 - 1 Main Components Lamps Option Option Battery 70 Pre-heat Warning Glow Plugs 71 Interior Light Glow Plugs 72 Right Hand Front Work Light Glow Plugs 73 Left Hand Front Work Light Glow Plugs 74 Work Light Switches Illumination (Front) Pre-heat Timer Relay...
Page 102 Electrics Section C Section C Circuit Diagram 6 - 2 6 - 2 32 33 34 35 36 3 4 5 16 17 A167872 9803/8500 Issue 3...
Page 103 Electrics Section C Section C Circuit Diagram 6 - 3 6 - 3 30 31 32 33 13 14 58 59 A206390 9803/8500 Issue 3...
Page 104 Electrics Section C Section C 6 - 4 Circuit Diagram 6 - 4 Main Components Lamps Option Option Battery 70 Pre-heat Warning Glow Plugs 71 Interior Light Pre-heat Timer Relay 72 Left Hand Side Light (Rear) Starter Switch 73 Right Hand Side Light (Rear) Auxiliary Neutral Start Relay 74 Left Hand Side Light (Front) Starter Solenoid...
Page 105 Electrics Section C Section C 6 - 5 Circuit Diagram 6 - 5 Main Components Lamps Option Option Battery Beacon Lamp Starter Solenoid Interior Light Starter Motor Front Work Lights Auxiliary Neutral Start Relay Rear Work Light Starter Switch Alternator Warning Glow Plug Relay Charge Pump Pressure Glow Plugs...
Page 106 Electrics Section C Section C Circuit Diagram 6 - 6 6 - 6 68 69 EQUIPMENT OPTIONS STANDARD 246/90901 OPTIONAL 9803/8500 Issue 2...
Page 107 Electrics Section C Section C Circuit Diagram 6 - 7 6 - 7 JOYSTICK SWITCH EQUIPMENT OPTIONS STANDARD 246/91000 OPTIONS CAB 1 OF 2 OPTIONS CANOPY 9803/8500 Issue 2...
Page 108 Electrics Section C Section C 6 - 8 Circuit Diagram 6 - 8 Main Components Lamps Option Option Battery Interior Light Starter Solenoid L.H. Dip Beam (Italian) Starter Motor R.H. Dip Beam (Italian) Auxiliary Neutral Start Relay L.H. Dip Beam (German) Starter Switch R.H.
Page 109 Electrics Section C Section C 6 - 9 Circuit Diagram 6 - 9 Main Components Lamps Option Option Engine Shut Off Relay Alternator Warning Warning Buzzer Charge Pump Pressure Alternator Hydraulic Oil Temperature Warning Hourmeter Engine Oil Pressure Warning Charge Pump Pressure Switch Water Temperature Warning Hydraulic Oil Temperature Switch Air Cleaner Warning...
Page 110 Electrics Section C Section C Circuit Diagram 6 - 10 6 - 10 88 89 84 85 EQUIPMENT OPTIONS STANDARD 246/91000 OPTIONS CAB 2 OF 2 OPTIONS CANOPY 9803/8500 Issue 1...
Page 111 Electrics Section C Section C Circuit Diagram 6 - 11 6 - 11 Note 2 Note 1 Note 2 EQUIPMENT OPTIONS 246/91402 STANDARD OPTIONAL 9803/8500 Issue 1...
Page 112 Electrics Section C Section C 6 - 12 Circuit Diagram 6 - 12 Main Components Lamps Option Option Battery Beacon Lamp Starter Solenoid Interior Light Starter Motor Front Work Lights Auxiliary Neutral Start Relay Rear Work Light Glow Plugs Alternator Warning Glow Plug Relay Charge Pump Pressure Starter Switch...
Page 113 Electrics Section C Section C 6 - 13 Circuit Diagram 6 - 13 Main Components Lamps Option Option Battery Interior Light Starter Solenoid L.H. Dip Beam (Italian) Starter Motor R.H. Dip Beam (Italian) Auxiliary Neutral Start Relay L.H. Dip Beam (German) Starter Switch R.H.
Page 114 Electrics Section C Section C Circuit Diagram 6 - 14 6 - 14 Note 1 Note 2 EQUIPMENT OPTIONS STANDARD 246/91502 OPTIONS CAB 1 OF 2 OPTIONS CANOPY 9803/8500 Issue 1...
Page 115 Electrics Section C Section C Circuit Diagram 6 - 15 6 - 15 25 26 Note 1 74 75 246/91502 2 OF 2 9803/8500 Issue 1...
Page 116 Electrics Section C Section C 6 - 16 Circuit Diagram 6 - 16 Main Components Lamps Option Option Hourmeter Alternator Warning Alternator Charge Pump Pressure Warning Buzzer Hydraulic Oil Temperature Warning Charge Pump Pressure Switch Engine Oil Pressure Warning Hydraulic Oil Temperature Switch Water Temperature Warning Engine Oil Pressure Switch Air Cleaner Warning...
Page 117 Electrics Section C Section C 7 - 1 Wire Number Identification 7 - 1 Wire/Harness Numbers - Explanation of: Each wire has its own unique number which is printed on the wire insulation every 50mm (2 inches). The wire numbers listed on the following pages identify the source, route and final destination of all the wires used on the machine.
Page 118 Electrics Section C Section C 7 - 2 Wire Number Identification 7 - 2 Panel/Cab Harness Wire No Wire Function Size (mm) 'Ignition' to Pre-heat Timer 3.0 (x2) 'Ignition' to Fuse 2 'Ignition' to Glow Plug Relay Fuse 3 Live to Fuse 4 Live Fuse 4 Live to Fuse 5 Live Fuse 3U Load to Horn Push Fuse 4U Load to Alternator Warn Light...
Page 119 Electrics Section C Section C 7 - 3 Wire Number Identification 7 - 3 Panel/Cab Harness (cont'd) Wire No Wire Function Size (mm) Pre-heat Timer Relay to Warning Light via Plug 1 Pin 11 Water Temperature Warning Light to Switch via Plug 1 Pin 12 Engine Oil Pressure Warning Light to Water Temperature Warning Light Water Temperature Warning Light to Air Filter Warning Light Air Filter Warning Light to Low Fuel Warning Light...
Page 120 Electrics Section C Section C 7 - 4 Wire Number Identification 7 - 4 Mainframe Harness Wire No Wire Function Size (mm) 'Ignition' to Glow Plug Relay Fuse 3U to Horn Push 'Ignition' Switch to Timer Relay Fuse 5U to ESOS Timer Relay to Starter Motor 3.0 (x2) Timer Relay to Glow Plug...
Page 121 Electrics Section C Section C 7 - 5 Wire Number Identification 7 - 5 Mainframe Harness (cont'd) Wire No Wire Function Size (mm) Brake Switch to Operational Solenoid Auxiliary Hydraulic Switch (Panel) to Splice Auxiliary Hydraulic Switch to Splice Auxiliary Hydraulic Switch to Joystick Switch Auxiliary Hydraulic Switch to Splice Splice to Joystick Hydraulic Switch Auxiliary Hydraulic Reverse to Splice...
Page 122 Section D Controls Section D Contents Page No. Safety Restraint Bar Description 1 - 1 Removal and Replacement 1 - 1 Locking Mechanism Removal and Replacement 1 - 1 Adjustment 1 - 1 Throttle Controls Description 2 - 1 Removal and Replacement 2 - 1 Adjustment 2 - 1...
Page 123: Safety Restraint Bar
Section D Controls Section D 1 - 1 Safety Restraint Bar 1 - 1 S168160-1 9803/8500 Issue 1...
Page 124: Description
Section D Controls Section D 1 - 2 Safety Restraint Bar 1 - 2 Description Locking Mechanism The object of the Safety Restraint Bar is to prevent Removal accidental operation of the hydraulic controls whilst the operator is not in his seat and ready to drive or manipulate If it is necessary to remove the safety restraint bar locking the machine.
Page 125: Throttle Controls
Section D Controls Section D 2 - 1 Throttle Controls 2 - 1 S168150D 9803/8500 Issue 1...
Page 126: Description
Section D Controls Section D 2 - 2 Throttle Controls 2 - 2 Description The combined foot and hand throttle controls (as shown at A) are designed to operate in conjunction with each other. Once the engine has been started, the hand throttle can be set to give an engine speed suitable for the operations to be performed.
Page 127: Throttle Cable
Section D Controls Section D 2 - 3 Throttle Controls 2 - 3 Throttle Cable Adjusting the Idle and Non-stalling Settings (Engine warm) Removal Loosen the nut 9 and deceleration screw 8 so that the latter Remove the inner cable from the slot in the accelerator lever. protrudes 13 to 14 mm from the face of the regulator casing.
Page 128 Hydraulics Section E Section E Contents Page No. Technical Data up to machine number 677000 1 - 1 Technical Data from machine number 677001 to 677999 1 - 4 Technical Data from machine number 678000 1 - 7 General Description 1 - 9 Hydraulic Contamination Hydraulic Fluid Quality...
Page 129 Hydraulics Section E Section E Contents Page No. Drive Motors Removal and Replacement - Drive Sprocket 13 - 1 - Motors 13 - 1 Dismantling and Assembly - Motors up to machine no. 676354 13 - 3 - Motors from machine no. 676355 13 - 5 Problem Solving Hydrostatic Transmission...
Page 130 Hydraulics Section E Section E Contents Page No. Schematic Hydraulic Circuit Servo machines up to serial number 675573 30 - 1 Servo machines from serial number 675574 to 677000 30 - 3 Servo machines from serial number 677001 to 677999 - Single Drive Lever Control 30 - 5 - Dual Drive Lever Control...
Page 131 Hydraulics Section E Section E 1 - 1 Technical Data 1 - 1 Up to machine no. 677000 Note: System Cleanliness is to be to ISO 16/13 - See page E/2 - 0 for guidance. Auxiliary Pump - Standard Type Gear type Displacement 48 l/min (10.5 UK gal, 12.7 US gal/min) at 3000 rev/min...
Page 132 Hydraulics Section E Section E 1 - 2 Technical Data 1 - 2 Loader Valve Block to machine no. 675573 Maximum Working Pressure 185 - 192 bar (2683 - 2785 lbf/in , 188 - 196 kgf/cm Maximum Return Pressure 20 bar (290 lbf/in , 20 kgf/cm Services Operated: - Spool 1...
Page 133 Hydraulics Section E Section E 1 - 3 Technical Data 1 - 3 Rams Bore Rod Dia Stroke Boom Lift 2.75 1.57 26.65 Crowd (80 x 40) 3.15 1.57 9.17 (100 x 50) 3.94 1.97 9.21 Compensating (60 x 30) 2.36 1.18 10.39...
Page 134 Hydraulics Section E Section E 1 - 4 Technical Data 1 - 4 From machine no. 677001 to 677999 Note: System Cleanliness is to be to ISO 16/13 - See page E/2 - 0 for guidance. Auxiliary Pump - Standard Type Gear type Displacement...
Page 135 Hydraulics Section E Section E 1 - 5 Technical Data 1 - 5 Loader Valve Block - Servo Machines Maximum Working Pressure 207 bar (3002 lbf/in , 211 kgf/cm Maximum Return Pressure 20 bar (290 lbf/in , 20 kgf/cm Services Operated: - Spool 1 Shovel Ram - Hydraulic Servo - Spool 2...
Page 136 Hydraulics Section E Section E 1 - 6 Technical Data 1 - 6 Rams Bore Rod Dia Stroke Boom Lift 2.75 1.57 26.65 Crowd (80 x 40) 3.15 1.57 9.17 (100 x 50) 3.94 1.97 9.21 Compensating (60 x 30) 2.36 1.18 10.39...
Page 137 Hydraulics Section E Section E 1 - 7 Technical Data 1 - 7 From machine no. 678000 Note: System Cleanliness is to be to ISO 16/13 - See page E/2 - 0 for guidance. Auxiliary Pump - Standard Type Gear type Displacement 54 l/min (11.9 UK gal, 14.2 US gal/min) at 3000 rev/min Maximum Working Pressure...
Page 138 Hydraulics Section E Section E 1 - 8 Technical Data 1 - 8 Loader Valve Block - Servo Machines Maximum Working Pressure 207 bar (3002 lbf/in , 211 kgf/cm Maximum Return Pressure 20 bar (290 lbf/in , 20 kgf/cm Services Operated: - Spool 1 Shovel Ram - Hydraulic Servo - Spool 2...
Page 139 Hydraulics Section E Section E 1 - 9 Technical Data 1 - 9 Rams Bore Rod Dia Stroke Boom Lift 2.75 1.57 26.65 Crowd (80 x 40) 3.15 1.57 9.17 (100 x 50) 3.94 1.97 9.21 Compensating (60 x 30) 2.36 1.18 10.39...
Page 140 Hydraulics Section E Section E 2 - 0 Hydraulic Contamination 2 - 0 Hydraulic Fluid Quality Contaminant Standards Construction machinery uses a large volume of fluid in the Dirt that damages your system is in many cases too small to hydraulic system for power transmission, equipment be seen with the eye.
Page 141 Hydraulics Section E Section E 2 - 1 Descriptions 2 - 1 Machine Neutral Circuit Oil is drawn from the tank T by the auxiliary pump P via a suction strainer S . The pump P delivers pressurised oil to the pressure reducing solenoid valve R and to the loader control valve L.
Page 142 Hydraulics Section E Section E 4 - 1 Descriptions 4 - 1 9803/8500 Issue 1...
Page 143 Hydraulics Section E Section E 4 - 2 Descriptions 4 - 2 9803/8500 Issue 1...
Page 144 Hydraulics Section E Section E 5 - 1 Descriptions 5 - 1 9803/8500 Issue 2*...
Page 145 Hydraulics Section E Section E 5 - 2 Descriptions 5 - 2 9803/8500 Issue 2...
Page 146 Hydraulics Section E Section E 5 - 3 Descriptions 5 - 3 9803/8500 Issue 2...
Page 147 Hydraulics Section E Section E 5 - 4 Descriptions 5 - 4 9803/8500 Issue 2...
Page 148 Hydraulics Section E Section E 5 - 5 Descriptions 5 - 5 9803/8500 Issue 2...
Page 149 Hydraulics Section E Section E 5 - 6 Descriptions 5 - 6 9803/8500 Issue 2...
Page 150 Hydraulics Section E Section E 5 - 7 Descriptions 5 - 7 9803/8500 Issue 2...
Page 151 Hydraulics Section E Section E 5 - 8 Descriptions 5 - 8 9803/8500 Issue 2...
Page 152 Hydraulics Section E Section E 5 - 9 Descriptions 5 - 9 9803/8500 Issue 1...
Page 153 Hydraulics Section E Section E 5 - 10 Descriptions 5 - 10 9803/8500 Issue 1...
Page 154 Hydraulics Section E Section E 6 - 1 Descriptions 6 - 1 PRESSURE IN JOYSTICK (LOADER) TANK SOL. SOL. (13,16) (14,17) BRAKE 13 14 16 17 EXTRACTS FROM THE WIRING A168083 DIAGRAM SCHEMATICS 9803/8500 Issue 4...
Page 155 Hydraulics Section E Section E 6 - 2 Descriptions 6 - 2 Pressure Reducing Solenoid Valve Pressure Reducing Solenoid Valve (machines without sequencing E.C.U.) (machines with sequencing E.C.U.) This valve controls the Safety Restraint Bar circuit, the door Note: The sequencing E.C.U. was fitted to machines from latch circuit, brake circuit, and pressure reduction circuit.
Page 156 Hydraulics Section E Section E 7 - 1 Descriptions 7 - 1 Drive Motor Operation Note: On the illustration below, the main parts of the motor Oil under pressure passes through the disc valve inlets to the inter-tooth chambers on one side of the gearwheel set. are shown slightly separated for purposes of explanation.
Page 157 Hydraulics Section E Section E 7 - 2 Descriptions 7 - 2 Drive Motor Brake Operation Each drive motor A incorporates a multiple disc brake pack B. The brakes are held 'on' by spring force and released by hydraulic pressure. They normally serve as holding brakes but can also be used as emergency brakes.
Page 158 TRANSMISSION OPERATION - NEUTRAL With the engine running but no drive selected, oil from pump P3 is fed through the loader valve 2 and Tank filter F1 to main pumps P1 and P2. A small amount Cooler Loader Valve of oil flows through the chargel valve Pa, enters the Filter Pressure Test Points pump casing and is returned via line z and through...
Page 159 TRANSMISSION OPERATION - FORWARD When the joystick 8 is moved to select forward drive spool 8b is operated allowing oil from pump P3 to Tank Cooler pass via shuttle valves 8e to the swash plate servos Loader Valve Filter on pumps P1 and P2. The swash plates are tilted Pressure Test Points Main Pump causing flow to pass to the motors M1 and M2 and...
Page 160 Hydraulics Section E Section E 9 - 1 Pumps 9 - 1 Removal and Replacement Replacement Note: The illustration shows an early pump but although later pumps are visually different the same procedure applies. Using suitable lifting tackle, ease the pump unit into position, Removal making sure that the pump unit/engine couplings engage smoothly and completely.
Page 161 E. The inner section A is tightened onto the pump shaft spline with cap screw D. Coat threads of capscrew D with JCB Threadlocker and Sealer and torque tighten to 49 Nm (36 lbf ft, 5 kgf m). Coat threads of capscrews E with JCB Threadlocker and Sealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).
Page 162 Hydraulics Section E Section E 9 - 3 Pumps 9 - 3 Start-Up Procedure Fill the hydraulic tank with the correct fluid (see page 3/1 - 1), via a 10 micron filter (no by-pass). The following start-up procedure should always be followed Check that the pump inlet line from the hydraulic filter to the when starting up a new installation or when restarting an pump unit is filled with fluid, by slackening the hose...
Page 163 Hydraulics Section E Section E 10 - 1 Pumps 10 - 1 168150 9803/8500 Issue 1...
Page 164 Hydraulics Section E Section E 10 - 2 Pumps 10 - 2 Hydrostatic Pump Dismantling and Assembly Separating the Front and Rear Pumps The information on this page covers the dismantling and The front and rear pumps are secured together by four assembly of those 'auxiliary' components which are capscrews 18.
Page 165 Hydraulics Section E Section E 10 - 3 Pumps 10 - 3 168030 9803/8500 Issue 1...
Page 166 Hydraulics Section E Section E 10 - 4 Pumps 10 - 4 Hydrostatic Pump Endcaps Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Each endcap 8, 9 is secured to its pump by four capscrews 2.
Page 167 Hydraulics Section E Section E 10 - 5 Pumps 10 - 5 168160 9803/8500 Issue 1...
Page 168 Hydraulics Section E Section E 10 - 6 Pumps 10 - 6 Hydrostatic Pump Note: The illustration shows the pump as fitted to servo machines. On manual machines, items 28 to 45 are not fitted and a manual lever is fitted in place of item 33. Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.
Page 169 Hydraulics Section E Section E 10 - 7 Pumps 10 - 7 Fault Finding Servo machines up to serial no. 676354 Machine veers to one side when travelling. This condition may be corrected by adjusting the pump servo units but before attempting this, carry out the following preliminary checks.
Page 170 Hydraulics Section E Section E 10 - 8 Pumps 10 - 8 Control Adjustment Manual machines If the machine continues to move when neutral is slected and Start the engine and allow to idle. also if the installation has been disturbed, the manual controls should be adjusted as detailed below.
Page 171 Hydraulics Section E Section E 10 - 8 Pumps *10 - 8 Hydrostatic Pump from machine no. 676355 Dismantling and Assembly Following a complete rebuild of this pump it is necessary for it to be set up on a dynamic test jig. Because of this it is recommended that no dismantling work is carried out beyond that covered in the following pages.
Page 172 Hydraulics Section E Section E 10 - 9 Pumps *10 - 9 Hydrostatic Pump from machine no. 676355 Charge Check and High Pressure Relief Valves Dismantling and Assembly The charge check and high pressure relief valves are identical. The procedure for dismantling and assembly is, therefore, the same for both valves.
Page 173 Hydraulics Section E Section E 10 - 10 Pumps *10 - 10 Hydrostatic Pump from machine no. 676355 Charge/Anti-stall Valve Dismantling and Assembly Mark the plug 1, locknut 2 and the pump body so as to approximately maintain the original adjustment. Loosen locknut 2 and unscrew plug 1 from pump body Remove O-ring 3 from plug 1 and discard O-ring.
Page 174 Hydraulics Section E Section E 10 - 11 Pumps *10 - 11 Hydrostatic Pump from machine no. 676355 Pump Neutral Adjustment This procedure may be carried out if the machine creeps when the drive joystick is in the neutral position. This fault may be due to an incorrect neutral setting of the servo piston.
Page 175 Hydraulics Section E Section E 11 - 1 Pumps 11 - 1 167750 9803/8500 Issue 2...
Page 176 Assembly Fit the pressure loading ring/backing ring 10 and sealing rings 11 to the flange 2 and cover 8. A little grease (JCB MPL Grease) in the grooves will help retain them. Hold the flange 2 in a soft jawed vice with the sealing rings facing upwards and assemble the body 3.
Page 177 Hydraulics Section E Section E 11 - 3 Pumps 11 - 3 291090 9803/8500 Issue 1...
Page 178 Hydraulics Section E Section E 11 - 4 Pumps 11 - 4 Auxiliary Pump (High-flow machines) Dismantling and Assembly When Assembling Note: Before removing and dismantling the pump, check flow Renew all seals. Hold them in position with grease during and pressure.
Page 179 Hydraulics Section E Section E 13 - 1 Drive Motors 13 - 1 167720 S167720A 9803/8500 Issue 1...
Page 180 Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Apply JCB Threadlocker & Sealer to bolts 5 before fitting. Examples of protective clothing are: a hard hat, safety Apply JCB High Strength Retainer to capscrews B before shoes, safety glasses, a well fitting overall, ear- fitting.
Page 181 Hydraulics Section E Section E 13 - 3 Drive Motors 13 - 3 S167730A S167730 S167730B 9803/8500 Issue 2...
Page 182 Hydraulics Section E Section E 13 - 4 Drive Motors 13 - 4 Dismantling and Assembly The numerical sequence shown is a guide to dismantling. Do the following to ensure correct alignment of the For assembly the sequence should be reversed. gearwheel set components: Dismantling Mark any spline peak on the inner gear 18 that lies...
Page 183 Hydraulics Section E Section E 13 - 5 Drive Motors 13 - 5 S243720 S243870 9803/8500 Issue 1...
Page 184 Remove O-ring 32 from rear case 21. Discard the O-ring. Thoroughly degrease capscrews 75 and 33 and mating parts, then assemble using JCB Threadlocker and Sealer. Make a note of the position of stop pin 23 in the slot in rear case 21 then remove the stop pin.
Page 185 Position drive shaft 1 vertically on a press. Warm bearing cone 8 and press into position on the shaft. Pack the front bearing cone with JCB HP Grease and assemble the front cover onto the shaft, taking care not to damage the lips of seal 11 on the splines of the shaft.
Page 186 Hydraulics Section E Section E 14 - 1 Problem Solving 14 - 1 Hydrostatic Transmission Before carrying out any problem solving or any tests on the machine, make sure that the hydraulic system is filled to the correct level with the correct grade of hydraulic oil (see Section 3) and that the system is at the correct working temperature. PROBLEM CAUSE (servo machines) CAUSE (manual machines)
Page 187 Hydraulics Section E Section E 14 - 2 Problem Solving 14 - 2 KEY TO CAUSE REMEDY PAGE REF. Mechanical brake failure Check brake components (worn plates, spring damage, etc.). E13-3, E13-5 Motor seal leakage Check motor case drain for confirmation of seal leakage E14-8 (compare one motor with the other).
Page 188 Hydraulics Section E Section E 14 - 3 Problem Solving 14 - 3 Checking for Faulty Pump or Motor If the transmission operates or is faulty on one side only then To ensure correct replacement after the test is complete, swop the motor feed hoses to check if the fault is with the mark the motor feed hoses A and B for the right hand pump or motor.
Page 189 Hydraulics Section E Section E 14 - 4 Problem Solving 14 - 4 Checking Wheel Speed The pump output and general efficiency of the drive system may be checked by raising the machine off the ground and checking the wheel speeds using a stroboscopic meter. ! WARNING The following procedure requires the machine to be disabled (wheels raised off the ground, work function...
Page 190 Hydraulics Section E Section E 14 - 5 Problem Solving 14 - 5 Machine veers to one side when travelling. This condition may be corrected by adjusting the pump servo units but before attempting this, carry out the following preliminary checks.
Page 191 Hydraulics Section E Section E 14 - 6 Problem Solving 14 - 6 Machine veers to one side when travelling (continued). Servo unit adjustment - machines from serial no. 676355 If the machine does not travel in a straight line, proceed as follows: Fault Machine veers excessively to left in forward travel...
Page 192 Hydraulics Section E Section E 14 - 7 Problem Solving 14 - 7 Machine veers to one side when travelling (continued). Adjusting the Manual Lever Stops On manual machines, when the control lever is moved fully forward, stop bolt A contacts block C, limiting the amount of lever movement (illustration shows right hand lever).
Page 193 Hydraulics Section E Section E 14 - 8 Problem Solving 14 - 8 Checking Motor Leakage Rate If the motor speed is low and the pump output is normal, the cause could be excessive internal wear in the motor which would result in high leakage of oil into the motor casing.
Page 194 Hydraulics Section E Section E 14 - 9 Problem Solving 14 - 9 Pump Main Pressure Test Points Illustration X shows the Series 40 pump which is fitted to Motor feed pressure test points servo machines up to serial no. 676354 and all manual machines.
Page 195 Hydraulics Section E Section E 14 - 10 Problem Solving 14 - 10 Checking Brake Circuit Pressure The built in brakes in the motors are released by hydraulic Connect a 0 - 40 bar (0 - 600 lb/in , 0 - 42 kg/cm pressure.
Page 196 Hydraulics Section E Section E 14 - 11 Problem Solving 14 - 11 Checking the Joystick Hydraulic Lines If the machine does not respond to joystick movements, If the gauge shows no or little pressure it could indicate a check the hydraulic supply to and from the joystick as follows: fault in the charge pressure relief valve in the hydrostatic pump or the pressure reducing solenoid valve C.
Page 197 Hydraulics Section E Section E 16 - 1 Valves 16 - 1 S167681 S267990 9803/8500 Issue 2...
Page 198 Hydraulics Section E Section E 16 - 2 Valves 16 - 2 Loader Valve Removal On machines prior to serial number 677001 (upper illustration), remove the seat and floor plate. On machines after 677001 (lower illustration), open the engine compartment rear door and top cover. ! WARNING Hydraulic Pressure It is not possible to vent all residual pressure.
Page 199 Hydraulics Section E Section E 16 - 3 Valves 16 - 3 S167672 9803/8500 Issue 3...
Page 200 Hydraulics Section E Section E 16 - 4 Valves 16 - 4 Loader Valve Dismantling Always work on a clean, dirt free surface. Assembly Remove the check valve from the inlet port A and the Assembly is a reversal of the dismantling procedure. plug from port B.
Page 201 M.R.V. or A.R.V.'s. Each valve should be renewed as a unit if a component is defective. Renew all 'O' rings. Lubricate parts with JCB 'Special' Hydraulic Fluid before assembly. The M.R.V. can be tested/adjusted in situ (see page E/16 - 6).
Page 202 Hydraulics Section E Section E 16 - 6 Valves 16 - 6 Pressure Testing - Main Relief Valve (M.R.V.) - In Situ Connect a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm pressure gauge to test connector A located on the left-hand end of the loader valve block.
Page 203 Hydraulics Section E Section E 16 - 7 Valves 16 - 7 Pressure Testing - Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump Insert the A.R.V. into the test block, part no. 892/00252. Connect hand pump 892/00223 and a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm ) pressure gauge.
Page 204 Hydraulics Section E Section E 16 - 8 Valves 16 - 8 316960 316950 9803/8500 Issue 2...
Page 205 On machines after serial number 678316, apply 2 or 3 drops spools as shown at X. The spool is prevented from moving of JCB Threadlocker & Sealer to threads of shoulder bolt 30 unless the solenoid is energised. All other components are after degreasing threads.
Page 206 Hydraulics Section E Section E 16 - 10 Valves 16 - 10 Loader Valve Dismantling Assembly The illustration below shows a typical valve section with servo operated spool. Assembly is a reversal of the dismantling procedure. Always work on a clean, dirt free surface. Renew all seals and 'O' rings.
Page 207 Hydraulics Section E Section E 16 - 11 Valves 16 - 11 Loader Valve Dismantling Assembly The illustration below shows a valve section with electrically Assembly is a reversal of the dismantling procedure. operated spool. Three spool loader valves will have this section in the third spool position for operating optional Renew all seals and 'O' rings.
Page 208 Lubricate parts with JCB 'Special' Hydraulic Fluid before assembly. The M.R.V. can be tested/adjusted in situ (see page E/16 - 13).
Page 209 Hydraulics Section E Section E 16 - 13 Valves 16 - 13 Pressure Testing - Main Relief Valve (M.R.V.) - In Situ Connect a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm pressure gauge to test connector A located on the left-hand end of the loader valve block.
Page 210 Hydraulics Section E Section E 16 - 14 Valves 16 - 14 Pressure Testing - Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump Insert the A.R.V. into the test block, part no. 892/00923. Connect hand pump 892/00223 and a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm ) pressure gauge to the pressure port P.
Page 211 Hydraulics Section E Section E 17 - 1 Valves 17 - 1 Check Valve The check valve consists of a plug A, plus a poppet and spring B in a body C. The minimum opening pressure is 8 bar (116 lbf/in To adjust the opening pressure, screw plug A in or out of the body C as required.
Page 212 Hydraulics Section E Section E 18 - 1 Valves 18 - 1 S204980 9803/8500 Issue 2...
Page 213 2 (see below). Replace solenoids on cartridge 3, apply a small amount of JCB Threadlocker & Sealer to the coil retaining nut 4 and torque tighten to 5 - 7 Nm (3.7 - 5.2 lbf ft, 0.5 - 0.7 kgf m).
Page 214 Hydraulics Section E Section E 18 - 3 Valves 18 - 3 Brake Valve Dismantling Unscrew the knurled nut 2 and remove ‘O’ ring 3, withdraw the solenoid 4 and ‘O’ ring 5. Hold the solenoid valve body 6 in a vice, using the spanner flats A, remove spindle 7 and ‘O’...
Page 215 Hydraulics Section E Section E 20 - 1 Servo Joysticks 20 - 1 S167960 9803/8500 Issue 1...
Page 216 Hydraulics Section E Section E 20 - 2 Servo Joysticks 20 - 2 Removal Note: Only the right-hand (R.H.) joystick is shown in the illustration. The other joystick is removed and replaced in the same way. Ensure that the engine is stopped and all hydraulic pressure is released from the system.
Page 217 Hydraulics Section E Section E 20 - 3 Servo Joysticks 20 - 3 167950 9803/8500 Issue 1...
Page 218 Hydraulics Section E Section E 20 - 4 Servo Joysticks 20 - 4 Dismantling Assembly The numerical sequence is intended as a guide to Lubricate all parts with hydraulic fluid before assembly. 'O' dismantling, assembly is the reverse of this sequence. rings and seals should be lightly coated with vaseline prior to assembly.
Page 219 Replacement is a reversal of the removal procedure. Grease Make sure that lifting equipment is in good condition. all pins and securing bolts with JCB Special MPL Grease. Make sure that lifting tackle complies with all local Torque securing bolts to 56 Nm (5.7 kg fm, 42 lbf ft).
Page 220 Hydraulics Section E Section E 23 - 2 Rams 23 - 2 Crowd Ram Removal ! WARNING ! WARNING Hydraulic Pressure Make the machine safe before getting beneath it. Park It is not possible to vent all residual pressure. Loosen the the machine on level ground.
Page 221 Hydraulics Section E Section E 23 - 3 Rams 23 - 3 S167800 9803/8500 Issue 1...
Page 222 Apply JCB Activator to the threads of the piston head 6. Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker.
Page 223 Hydraulics Section E Section E 25 - 1 Hydraulic Filter 25 - 1 The hydraulic filter assembly is secured to the machine with two bolts A and by a solid pipework return connection B to the hydraulic tank. The return to tank incorporates a relief valve which dumps hydraulic fluid directly to tank if the element C becomes blocked.
Page 224 Hydraulics Section E Section E 27 - 1 Hydraulic Tank 27 - 1 Suction Strainer ! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the boom. Apply the parking brake, put the transmission in neutral and stop the engine.
Page 225 Hydraulics Section E Section E 30 - 1 Schematic Hydraulic Circuit 30 - 1 Component Key - up to machine no. 675573 Standard Circuit Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank...
Page 226 Hydraulics Section E Section E 30 - 2 Schematic Circuit 30 - 2 A167843 9803/8500 Issue 4...
Page 227 Section E Hydraulics Section E 30 - 3 Schematic Circuit 30 - 3 A167845 9803/8500 Issue 2...
Page 228 Hydraulics Section E Section E 30 - 4 Schematic Hydraulic Circuit 30 - 4 Component Key - from machine no. 675574 to 677000 Standard Circuit Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank...
Page 229 Hydraulics Section E Section E 30 - 5 Schematic Hydraulic Circuit 30 - 5 Component Key - Servo machines from serial no. 677001 to 677999 Single Drive Lever Control Standard Circuit Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor...
Page 230 Section E Hydraulics Section E 30 - 6 Schematic Circuit 30 - 6 A257392 9803/8500 Issue 3...
Page 231 Section E Hydraulics Section E 30 - 7 Schematic Circuit 30 - 7 A257372 9803/8500 Issue 3...
Page 232 Hydraulics Section E Section E 30 - 8 Schematic Hydraulic Circuit 30 - 8 Component Key - Servo machines from serial no. 677001 to 677999 Dual Drive Lever Control Standard Circuit Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor...
Page 233 Hydraulics Section E Section E 30 - 9 Schematic Hydraulic Circuit 30 - 9 Component Key - Manual machines from serial no. 677001 to 677999 Standard Circuit Cooler (see note 2) Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer...
Page 234 Section E Hydraulics Section E 30 - 10 Schematic Circuit 30 - 10 A257152 9803/8500 Issue 3...
Page 235 Hydraulics Section E Section E 30 - 11 Schematic Circuit 30 - 11 Servo machines from serial no. 678000 Component Key - Standard Circuit Cooler Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer Tank...
Page 236 Hydraulics Section E Section E 30 - 12 Schematic Circuit 30 - 12 Servo machines from serial no. 678000 Component Key - High-flow Circuit Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer...
Page 237 Hydraulics Section E Section E 30 - 13 Schematic Circuit 30 - 13 Macchine con comandi manuali dal n. 678000 Legenda componenti - Circuito normale Scambiatore di calore Filtro Pompa principale Collegate in tandem Pompa principale Pompa ad ingranaggi ausiliaria Motore comando trasmissione sinistro Motore comando trasmissione destro Filtro di aspirazione...
Page 238 Hydraulics Section E Section E 30 - 14 Schematic Circuit 30 - 14 Manual machines from serial no. 678000 Component Key - High-flow Circuit Cooler Filter High-flow Filter Main Pump Run in Tandem Main Pump Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Suction Strainer High-flow Pump Suction Strainer...
Page 239 Transmission Section F Section F Contents Page No. Tyres and Wheels Roadwheels 1 - 1 - Removal and Replacement 1 - 1 Wheel Hub Assembly up to machine no. 676701 1 - 2 - Removal and Replacement 1 - 2 - Dismantling and Assembly 1 - 4 Wheel Hub Assembly from machine no.
Page 240 Transmission Section F Section F 1 - 1 Tyres and Wheels 1 - 1 Roadwheels ! WARNING Removal A raised and badly supported machine can fall on you. Procedure is the same for all four wheels. Position the machine on a firm, level surface before raising one end.
Page 241 Transmission Section F Section F 1 - 2 Tyres and Wheels 1 - 2 167811 167861 9803/8500 Issue 2...
Page 242 E. Remove the hub assembly from the chassis. Remove and discard seal F. Replacement Replacement is a reversal of the removal procedure. A new 'O' ring F must be fitted. (Grease with JCB MPL Grease.) Adjust the drive chain(s) (see Section 3, Routine Maintenance) Torque tighten nuts B to 98 Nm (72 lbf ft, 10 kgf m).
Page 243 Transmission Section F Section F 1 - 4 Tyres and Wheels 1 - 4 167851 9803/8500 Issue 2...
Page 244 Assembly The numerical sequence shown in the dismantling procedure should be reversed. Lubricate all bearings and seals with JCB Special MPL Grease before assembly. When assembling the sprocket note that it is dished to offset the teeth from the mounting face. Therefore, on the front hub...
Page 245 Transmission Section F Section F 1 - 6 Tyres and Wheels 1 - 6 S255770 S255790 S255780 9803/8500 Issue 1...
Page 246 Remove the nut B and pull the hub assembly out; remove the Lubricate all bearings and seals with JCB Special HP Grease chain from the sprocket 2. Remove the hub assembly from before assembly. the chassis. Remove and discard seal 9.
Page 247 Brakes Section G Section G Contents Page No. Preparation for Towing/Winching up to machine number 676354 1 - 1 from machine number 676355 1 - 2 9803/8500 Issue 2...
Page 248 Connect a hydraulic hand pump to the T-connector B in the hydraulic feed to the brake circuit. It is only possible to tow or winch the JCB Skid Steer Loader for short distances at slow speed in a straight line. This is...
Page 249 Brakes Section G Section G 1 - 2 1 - 2 Preparation for Towing/Winching from machine no. 676355 After Towing/Winching The braking system components on this machine are integral Remove the brake piston pullers and refit plugs B. Refit with the hydraulic drive motors and are covered in Section E the floor plates.
Page 250 Engine Section K Section K Contents Page No. Specification Technical Data - Peugeot Engine 1 - 1 Technical Data - JCB Diesel Engine 1 - 2 Removal and Replacement 2 - 1 9803/8500 Issue 3*...
Page 251 Speeds Loaded No. Load Oil Pressure (hot) Model Max. rev/min Max. rev/min (at loaded speeds) 110 °C (230 °F) Robot 150 2630 3000 3.6 bar (52.2 lbf/in , 3.7 kgf/cm Robot 165 2630 3000 3.7 bar (53.7 lbf/in , 3.8 kgf/cm...
Page 252 Engine Section K Section K 1 - 2 Specification 1 - 2 Technical Data - JCB Diesel engine Type 4 cylinder in-line, compression ignition, naturally aspirated. Bore (nominal) 84 mm (3.31 in) Stroke 100 mm (3.94 in) Swept Volume 2216 cm (135.2 in...
Page 253 Engine Section K Section K 2 - 1 Removal and Replacement 2 - 1 S167990 9803/8500 Issue 1...
Page 254 Note: If the mounting brackets are removed from the engine Disconnect and remove the battery. block it is necessary to use JCB Lock and Seal when re- installing the mounting bolts B before torque tightening. Remove the exhaust and air filter assembly.

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Robot 165

jcb ROBOT 150 Service Manual

General Information Section 1

Routine Maintenance Section 3

Optional Attachments Section a

Electrics Section C

Section D Controls Section D

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