Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Maintenance

Section A - Attachments

Section B - Body and Framework

Section C - Electrics

Section D - Controls

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section J - Tracks

Section K - Engine

Publication No.

9803/9450-1

World Class

Customer Support

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Summary of Contents for jcb Robot 160

Page 1 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 2 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 3 Section 1 - General Information Page left intentionally blank 1 - 0 1 - 0 9803/9450-1...
Page 4 Section 1 - General Information Contents Page No. Introduction About this Publication ................1 - 1 Identifying your Machine ........................ 1 - 2 Machine Model and Serial Number ............ 1 - 2 Machine Identification Plate ............... 1 - 2 Typical Product Identification Number (PIN) ........1 - 3 Engine Number ..................
Page 5 Section 1 - General Information Contents Page No. 1 - ii 1 - ii...
Page 6 Section 1 - General Information Introduction About this Publication This publication is designed for the benefit of JCB All sections are listed on the front cover; tabbed divider Distributor Service Engineers who are receiving, or have cards align directly with individual sections on the front received, training by JCB Technical Training Department.
Page 7 This manual provides information for the following wheeled models in the JCB Skid Steer Loader Range. – Robot 160 serial number 1602000 to 1604999. – Robot 160HF serial number 1602000 to 1604999. – Robot 170 serial number 1602000 to 1604999.
Page 8 Section 1 - General Information Identifying your Machine Typical Product Identification Number (PIN) JCB 160 888001 World Manufacturer Identification Machine Model Machine Type (S = Standard, H = High-flow) Build Type (A = Canopy, B = Cab) Year of Manufacture:...
Page 9 For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Page 10 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
Page 11 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
Page 12 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...
Page 13 Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
Page 14 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 4. Hoses 4-B screwed into adaptors 4-A seal onto an `O' ring Note: Dimension 4-D will vary depending upon the torque 4-C which is compressed into a 45° seat machined into the applied.
Page 15 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
Page 16 Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 5. `Torque Stop' Hoses 5-B screwed into adaptors 5-A seal Stop' Hoses have an additional shoulder 5-D, which acts onto an 'O' ring 5-C which is compressed into a 45° seat as a physical stop.
Page 17 Note: Tools other than those listed will be required. It is removal and replacement of Body and Framework parts. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.
Page 18 Hand Cleaner - special blend for the removal of Cartridge Gun - hand operated - essential for the polyurethane adhesives. application of sealants, polyurethane materials etc. JCB part number - 4104/1310 (454g; 1 lb tub) JCB part number - 892/00845 Fig 8. Fig 9.
Page 19 Note: 110V models available upon request - Ensure suction cups are protected from damage during contact JCB Technical Service. storage. JCB part number: JCB part number - 892/00842 992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V Fig 13. Fig 12.
Page 20 'L' Blades - 25 mm (1 in) cut - replacement blades for cut- (below) to cut out broken glass. out knife (above). JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off) Fig 16. Fig 17. Braided Cutting Wire - consumable heavy duty cut-out Long Knife - used to give extended reach for normally wire used with the glass extraction tool (above).
Page 21 JCB part number - 892/00847 JCB part number - 926/15500 (unit quantity = 500 off) 1 - 16 1 - 16 9803-9450-1...
Page 22 Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 20. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut 826/01105 M10 x 26mm Rivet Nut Installation Tool Available from:...
Page 23 The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing electrics. These tools are available from JCB expected that such general tools will be available in any Service.
Page 24 Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Tool Detail Reference Section C - Electrics Fig 21. 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 1 - 19 1 - 19...
Page 25 Note: Tools other than those listed will be required. It is testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.
Page 26 Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Description Tool Detail Reference Number 892/00057 Blanking Plug K Fig 30. ( T 1-25) 892/00059 Blanking Plug K Fig 30. ( T 1-25) 892/00060 Blanking Plug K Fig 30. ( T 1-25) 892/00074 Female Connector K Fig 33.
Page 27 Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Description Tool Detail Reference Number 992/09700 Spanner K Fig 34. ( T 1-26) 993/68100 Slide Hammer K Fig 35. ( T 1-26) The following parts are replacement items for kits and would normally be included in the kit numbers quoted above.
Page 28 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Tool Detail Reference Section E- Hydraulics 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point Fig 24.
Page 29 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 27. Hand Pump Equipment 892/00223 Hand Pump Fig 25. Flow Test Equipment 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00268 Flow Monitoring Unit 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/ 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point min)
Page 30 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 29. Male Adapters - BSP x BSP Fig 31. Male Cone Blanking Plug 1606/0003 3/8 in x 1/4 in 816/00294 1/4 in BSP 1604/0003 3/8 in x 3/8 in 816/00189 3/8 in BSP 1606/0004 1/2 in x 1/4 in 816/00190 1/2 in BSP...
Page 31 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 10mm 20mm Fig 33. Female Connectors 892/00074 3/8 in BSP x 3/8 in BSP 892/00075 1/2 in BSP x 1/2 in BSP 892/00077 3/4 in BSP x 3/4 in BSP 110mm 175mm Fig 36.
Page 32 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 38. Pump Drive Alignment Tool 331/22966 Fig 39. P.M.S. Test Button 701/80490 Fig 40. P.M.S. Potentiometer 716/30334 (if required, add knob 331/21736) 1 - 27 1 - 27 9803-9450-1...
Page 33 A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
Page 34 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 35 Section 2 - Care and Safety Page left intentionally blank 2 - 0 2 - 0 9803/9450-1...
Page 36 Section 2 - Care & Safety Contents Page No. Safety Check List Safety Notices ..................2 - 1 Safety Check List ..................2 - 2 Safety - Yours and Others ..............2 - 2 General Safety ................... 2 - 2 Operating Safety ................
Page 37 Section 2 - Care & Safety Contents Page No. 2 - ii 2 - ii...
Page 38 Section 2 - Care & Safety Safety Check List 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 extreme hazard exists.
Page 39 If you do not understand with a potentially explosive atmosphere. Sparks in anything, ask your employer or JCB dealer to explain such an area could cause an explosion or fire it. Keep the Operator Manual clean and in good resulting in death or serious injury.
Page 40 Breathing the machine exhaust gases can harm and altered in any way which could affect or invalidate any possibly kill you. Do not operate the machine in closed of these requirements. For advice consult your JCB spaces without making sure there is good ventilation. Distributor.
Page 41 Do not machine potentially explosive INT-2-2-3 atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. WARNING INT-2-1-14 Parking An incorrectly parked machine can move without an CAUTION operator. Follow the instructions in the Operator Manual to park the machine correctly.
Page 42 5-5-1-1_2 5-3-1-12_3 WARNING WARNING Use only the JCB approved attachments that are Keep the machine controls clean and dry. Your hands specified for your machine. Operating with non- and feet could slide off slippery controls. If that specified attachments can overload the machine, happens you could lose control of the machine.
Page 43 Section 2 - Care & Safety Safety Check List Safety Check List CAUTION WARNING One-Fork Lifting Forks/Turning A load lifted on one fork can slip off. Never lift a load The forks extend beyond the end of the boom. Make with one fork.
Page 44 Section 2 - Care & Safety Safety Check List Safety Check List WARNING WARNING Controls Entering/Leaving You or others can be killed or seriously injured if you Entering or leaving the cab or canopy must only be operate the control levers from outside the cab. made where steps and handrails are provided.
Page 45 Section 2 - Care & Safety Safety Check List Safety Check List Maintenance Safety WARNING If you try to charge a frozen battery, or jump start and WARNING run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the Communications battery electrolyte from freezing, keep the battery at Bad communications can cause accidents.
Page 46 Section 2 - Care & Safety Safety Check List Safety Check List WARNING WARNING Hydraulic Pressure Soft Ground Hydraulic fluid at system pressure can injure you. A machine can sink into soft ground. Never work Before connecting or removing any hydraulic hose, under a machine on soft ground.
Page 47 CAUTION WARNING 'O' rings, Seals and Gaskets Certain seals and gaskets (e.g. crankshaft oil seal) on Badly fitted, damaged or rotted 'O' rings, seals and JCB machines contain fluoroelastomeric materials gaskets can cause leakages and possible accidents. such Viton, Fluorel Technoflon.
Page 48 Prior to any work being carried out on components. systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as HYD-1-3 the sudden release of the hydraulic fluid or gas may cause injury. WARNING...
Page 49 Section 2 - Care & Safety Safety Check List Safety Check List WARNING Mast Safety Strut You can be killed or injured if the mast/carriage drops while you are working under it. Install the mast safety strut before working beneath a raised mast/carriage. 9-1-4-2 WARNING Asbestos...
Page 50 STOP THE ENGINE. COULD RESULT IN INJURY OR DEATH. START THE ENGINE. REMOVE THE STRUT: CONTACT ANY JCB DEALER FOR REPLACEMENT SLOWLY LOWER THE ARM ONTO THE SAFETY STRUT. RELEASE THE SECURING STRAP. REMOVE THE SAFETY STRUT FROM THE LIFT RAM.
Page 51 Section 2 - Care & Safety Safety Check List Safety Decals Page left intentionally blank 2 - 14 2 - 14 9803-9450-1...
Page 52 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 53 Section 3 - Maintenance Page left intentionally blank 3 - 0 3 - 0 9803/9450-1...
Page 54 Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ................3 - 1 Introduction ..................3 - 1 Owner/Operator Support ..............3 - 1 Service/Maintenance Agreements ............. 3 - 1 Lifting Regulations - Inspections and Tests ........3 - 1 Obtaining Replacement Parts .............
Page 55 Section 3 - Maintenance Contents Contents Page No. Fuel System ................... 3 - 40 Types of Fuel ..................3 - 40 Filling the Tank ................. 3 - 41 Changing the In-line Fuel Filter ............3 - 42 Draining the Fuel Filter ..............3 - 42 Changing the Fuel Filter Element .............
Page 56 Remember, only your JCB Distributor has access to the carried out by a JCB trained specialist. Only JCB vast resources available at JCB to help support you. In Distributor Service Engineers have been trained by JCB to addition, your Distributor is able to offer a variety of...
Page 57 This ensures that only JCB Factory trained, experienced and up-to-date Engineers supported with all of the available data and material provided only to a JCB Distributor will ensure a thorough and reliable standard. Obtaining Replacement Parts T3-004_2 We recommend you fit only JCB Genuine Parts.
Page 58 There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene Hygiene practices. JCB lubricants are not a health risk when used properly for Used Oil their intended purposes. Used engine crankcase lubricants contain harmful However, excessive or prolonged skin contact can remove contaminants.
Page 59 Section 3 - Maintenance Routine Maintenance Health and Safety First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice.
Page 60 Section 3 - Maintenance Routine Maintenance Health and Safety Battery Warning Symbols The following warning symbols may be found on the WARNING battery. Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the Symbol Meaning battery away from sparks and flames.
Page 61 Section 3 - Maintenance Routine Maintenance Health and Safety WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery.
Page 62 Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules Introduction A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.
Page 63 Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 ENGINE Coolant Quality and Level - Check Cooling System - Drain and Refill Oil level - Check - Change Oil and Filter (1)(2) Air Cleaner Dust Valve - Change...
Page 64 Section 3 - Maintenance Routine Maintenance Service Schedules Operation 1000 2000 HYDRAULICS - Sample/Change Oil Level - Check Oil Filter - Change Suction Strainer - Clean Ram Piston Rods for Damage/ Leaks - Check Hoses for Damage/ Leaks - Check Pipework for Damage/ Leaks - Check Breather...
Page 65 Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and Final Inspection Operation 1000 2000 6000 ENGINE Idle Speed - Check and Adjust Max. No-Load Speed - Check and Adjust Pulled down speed - Check Exhaust System Security - Check Exhaust Smoke - Check Air Inlet System Security...
Page 66 Section 3 - Maintenance Routine Maintenance Service Schedules Operation 1000 2000 6000 PAINTWORK Condition - Check REGISTRATION/CERTIFICATE SWL Stickers (UK) - Renew as Required - Check (1) Jobs which should only be done by a specialist. 3 - 11 3 - 11 9803/9450-1...
Page 67 Chain Case 17 (3.8) Engine oil Coolant Mixtures The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. T3-009_3 Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.
Page 68 Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used.
Page 69 Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine Park the machine on firm level ground, engage the parking directing the hose from the outside of the radiator. brake and set the transmission to neutral. Lower the Water will drain through the aperture at the base of attachments to the ground and stop the engine.
Page 70 Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Cab Interior Because the machine chassis is of sheet steel construction special provision is made for cleaning out the cab. At the rear of the footwell is a blanking plate A which can be removed for cleaning purposes.
Page 71 Section 3 - Maintenance Routine Maintenance Checking for Damage Checking for Damage T3-013 Inspect steelwork for damage. Note damaged paintwork for future repair. Make sure all pivot pins are correctly in place and secured by their locking devices. Ensure that the steps and handrails are undamaged and secure.
Page 72 Section 3 - Maintenance Routine Maintenance Seat Belt Seat Belt Checking the Seat Belt Condition and Security T3-008 WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.
Page 73 Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6 For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. 3 - 18...
Page 74 Section 3 - Maintenance Routine Maintenance Boom Safety Strut Boom Safety Strut Installing WARNING Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped).
Page 75 Section 3 - Maintenance Routine Maintenance Boom Safety Strut Removing WARNING You could be killed or injured if the loader control is accidentally operated. Make sure no-one comes near the machine while you remove the safety strut. 2-3-1-3 Make sure that the drive control is in the neutral (rest) position.
Page 76 Section 3 - Maintenance Routine Maintenance Greasing Greasing Greasing 10 Hours You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient.
Page 77 Section 3 - Maintenance Routine Maintenance Greasing Every 50 Hours Loader Arm Pivot Point Switch off the engine and ensure it cannot be started while WARNING you are doing this job. Never walk or work under raised equipment unless it Total of 2 grease points A (one each end of pin) is supported by a mechanical device.
Page 78 Section 3 - Maintenance Routine Maintenance Oiling Oiling Every 500 Hours Safety Restraint mechanism Switch off the engine and ensure it cannot be started while you are doing this job. Oil the moving parts of the safety restraint mechanism Throttle Pedal (if fitted) Switch off the engine and ensure it cannot be started while you are doing this job.
Page 79 Section 3 - Maintenance Routine Maintenance Access Panels Access Panels Engine Cover Closing Release stay B and lower the top cover. Opening and Closing Turn the handle to secure the top cover. Lock the Access to the engine compartment is provided by a hinged handle and remove the key.
Page 80 Section 3 - Maintenance Routine Maintenance Electrical System Electrical System Battery Connection Check the battery. The battery is mounted in the engine compartment. a If the terminal is dirty, clean the post. Fig 10. b If the terminal post is corroded and generates white powder wash the terminal with hot water.
Page 81 If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply.
Page 82 Section 3 - Maintenance Routine Maintenance Electrical System The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on. Set all switches in the cab to off.
Page 83 Section 3 - Maintenance Routine Maintenance Electrical System Fuses and Relays Primary Fuses To further protect the machine wiring harnesses and electrical circuits, a primary fuse box is fitted to the battery positive terminal as shown at A. Remember to check the Individual Circuit Fuses as well as the primary fuses shown below.
Page 84 Section 3 - Maintenance Routine Maintenance Electrical System Individual Circuit Fuses Fuse Circuits Protected Size The electrical circuits are protected by fuses. The fuses are Front Wipers and Washers 15 Amp located behind a cover on the right hand side of the cab as Power Socket 7.5 Amp shown in the illustration.
Page 85 Section 3 - Maintenance Routine Maintenance Electrical System Relays The relays are located under fuse cover on the right hand side of the cab as shown in the illustration. Ignition Brake Lights, Alternator Park Brake, Horn Neutral Start Indicators Reverse Alarm Indicators/Attachment Changeover Solenoid Indicators/Attachment Changeover Solenoid Float...
Page 86 Section 3 - Maintenance Routine Maintenance Engine Air Filter Engine Air Filter Changing the Elements Fig 15. Note: In a dusty environment, the outer element may have CAUTION to be changed more frequently than the service schedule recommendation. A new inner element must be fitted at The outer element must be renewed immediately if the least every third time the outer element is changed.
Page 87 Section 3 - Maintenance Routine Maintenance Engine Air Filter Clean the inside the canister E and cover B. Carefully insert the new elements into the canister. Ensure they are pushed fully onto their spigots. Fit cover B with dust valve K at the bottom. Make sure that the wire is connected to the Air Filter Blocked switch G.
Page 88 Section 3 - Maintenance Routine Maintenance Engine Engine Checking the Oil Level CAUTION Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2 Park the machine on level ground and lower the attachments to the ground.
Page 89 Section 3 - Maintenance Routine Maintenance Engine Changing the Oil and Filter K Health and Safety ( T 3-3) WARNING Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer.
Page 90 Section 3 - Maintenance Routine Maintenance Engine Note: Old engine oil and filters should be disposed of in accordance with local Health and Safety regulations. Fig 19. Unscrew the filter canister E, using a chain wrench if necessary. Remember that it will contain some oil. Clean filter head F.
Page 91 Section 3 - Maintenance Routine Maintenance Engine Checking the Coolant Level WARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before checking the coolant level or checking the system.
Page 92 Section 3 - Maintenance Routine Maintenance Engine Changing the Coolant Park the machine on level ground. Stop the engine and let it cool down. Open the engine compartment top cover. Fig 22. Unscrew the cylinder block drain tap E. Fig 21. Carefully loosen the radiator filler cap B just enough to let any pressure escape.
Page 93 Section 3 - Maintenance Routine Maintenance Engine Fill the system at the filler cap B, using the necessary anti-freeze solution, up to the neck of the filler. K Coolant Mixtures ( T 3-12). Refit the filler cap B. Fill the expansion bottle A, using the necessary antifreeze solution, to the level indicated.
Page 94 Section 3 - Maintenance Routine Maintenance Engine Checking the Alternator Belt Tension Adjusting the Alternator Belt Park the machine on level ground. WARNING Stop the engine. Make sure the engine cannot be started. Disconnect the battery before doing this job. Open the engine compartment top cover.
Page 95 CAUTION Low Temperature Fuels Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a GEN-9-2 lower viscosity.
Page 96 Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or Consult your JCB distributor for advice about the use of working on the fuel system. Do not refuel with the Fatty Acid Methyl Ester fuels, as improper application may engine running.
Page 97 Section 3 - Maintenance Routine Maintenance Fuel System Changing the In-line Fuel Filter Draining the Fuel Filter The in-line fuel filter is located on the left side of the engine. The fuel filter is located in the engine compartment on the left hand side.
Page 98 Section 3 - Maintenance Routine Maintenance Fuel System Changing the Fuel Filter Element Stop the engine. Open the engine compartment top cover. K Engine Cover ( T 3-24). Place a receptacle under the filter to catch any fuel. Slacken tap B. Support the bowl C and unscrew bolt D.
Page 99 Section 3 - Maintenance Routine Maintenance Fuel System Bleeding the Fuel System If either the in-line filter or main filter has been disturbed it will be necessary to bleed air from the system. Slacken bleed screw N and operate the priming pump P by squeezing it until fuel spurts from the loosened connection with no entrapped air.
Page 100 CAUTION If the fluid is cloudy, then water or air has WARNING contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor Fluid Under Pressure immediately. Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under 12-5-1-4 pressure and wear protective glasses.
Page 101 Section 3 - Maintenance Routine Maintenance Hydraulic System Changing the Charge Filter Element The oil level should be checked when the oil is cool or cold. CAUTION Ensure that dirt etc. does not enter the hydraulic system during this job. 5-3-4-4 Stop the engine and wait until the system has cooled.
Page 102 Section 3 - Maintenance Routine Maintenance Hydraulic System Changing the Return Filter Element The oil level should be checked when the oil is cool or cold. CAUTION Ensure that dirt etc. does not enter the hydraulic system during this job. 5-3-4-4 Stop the engine and wait until the system has cooled.
Page 103 Section 3 - Maintenance Routine Maintenance Drive Chain Lubrication Drive Chain Lubrication Fig 34. The final drive to the wheels is by chains. A chain casing Stop the engine. on the right side of the machine houses four chains, two to the front wheels and two to the rear wheels.
Page 104 Section 3 - Maintenance Routine Maintenance Tyres and Wheels Tyres and Wheels Tyre Inflation T3-010 These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.
Page 105 Section 3 - Maintenance Routine Maintenance Tyres and Wheels Renewing Segments of Optional Non- Inflatable Tyres Non-inflatable tyres are available as an option. These tyres consist of a number of individual segments bolted to the wheel rim. Damaged segments can be renewed individually. Loosen and remove the four nuts and washers A (two each side of the wheel).
Page 106 Section 3 - Maintenance Routine Maintenance Tracks Tracks Track Adjustment Correct track tension is important for good performance and to prevent the tracks from dismounting. The track tension is controlled by the forward idler which is attached to a grease filled hydraulic cylinder. The track tension should be checked as follows: Position machine on a smooth flat surface Thoroughly clean the track, making sure that all...
Page 107 Section 3 - Maintenance Routine Maintenance Windscreen Washer (optional) Windscreen Washer (optional) Checking the Level Park the machine on firm level ground. Engage the park brake. Lower the attachments to the ground. Stop the engine. Remove the starter key. The windscreen washer filler A is in the panel in front of the cab.
Page 108 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 109 Section A - Attachments Page left intentionally blank A - 0 A - 0 9803/9450-1...
Page 110 Section A - Attachments Contents Page No. Hydraulic Connections General Information ................A - 1 Quick Release Couplings ............... A - 2 Connecting and Disconnecting ............A - 2 Connecting/Disconnecting Hydraulic Hoses ........... A - 4 Connecting the Hoses ............... A - 4 Disconnecting the Hoses ..............
Page 111 Section A - Attachments Contents Page No. A - ii A - ii...
Page 112 Section A - Attachments Hydraulic Connections General Information When fitting hydraulically operated optional attachments to the Robot the following points should be noted: When a Hammer or Earth Drill attachment is required a drain line must be fitted to the machine. These two attachments can only be used on machines with High-Flow circuit fitted.
Page 113 Section A - Attachments Hydraulic Connections Quick Release Couplings Quick Release Couplings T4-001 Connecting and Disconnecting wedge underneath the sleeve and destroy the coupling. Flat face quick release couplings allow the operator to – Don't damage the faces of the couplings - this can remove and install attachments swiftly and efficiently.
Page 114 Section A - Attachments Hydraulic Connections Quick Release Couplings Connecting Quick Release Couplings Remove any residual hydraulic pressure trapped in the service line hose. Wipe the two faces of the male and female couplings and make sure they are clean. Make sure that ball 1-C in the female coupling is located in one of its slots.
Page 115 Section A - Attachments Hydraulic Connections Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses Some attachments are hydraulically powered. The b Operate the Auxiliary Control to build up pressure following paragraphs describe how to connect and in the hoses. disconnect the hydraulic hoses safely. c Switch off the engine.
Page 116 Section A - Attachments Maintenance Shovels 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. Repair or replace as necessary. 6-in-1 Shovel Daily Maintenance Clean with the rest of the machine.
Page 117 Section A - Attachments Maintenance Pallet Forks Pallet Forks 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 118 Section A - Attachments Maintenance Manure/Silage Fork with Top Grab Manure/Silage Fork with Top Grab Attachment Frame The Manure/Silage fork is fitted with a top grab as standard. This gives extra security to the load while moving the machine. Some attachments, e.g. the Hammermaster, Earth Drill and Compactor, utilise an attachment frame for installation The grab is opened and closed by a hydraulic ram on a Skid Steer Loader.
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Page 120 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 122 Section B - Body & Framework Contents Page No. Loader Arm Removal and Replacement ..............B - 1 Removal .................... B - 2 Replacement ..................B - 3 Fasteners Rivet Nuts ....................B - 4 Fitting Procedure ................B - 5 B - i B - i...
Page 123 Section B - Body & Framework Contents Page No. B - ii B - ii...
Page 124 Section B - Body & Framework Loader Arm Removal and Replacement Loader Arm Removal and Replacement B - 1 B - 1 9803-9450-1...
Page 125 Section B - Body & Framework Loader Arm Removal and Replacement Fig 1. Removal Remove nut 14 and bolt 15. Remove circlips 16 and washers 17 from each end of the lift arm pivot. Drift out pivot pin 18. Park the machine on firm level ground and stop the engine. Chock all four wheels to prevent accidental machine The loader arm can now be manoeuvred from the machine movement.
Page 126 Section B - Body & Framework Loader Arm Removal and Replacement Replacement Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL grease. Reconnect all hoses and bleed the hydraulic system. B - 3 B - 3...
Page 127 Section B - Body & Framework Fasteners Rivet Nuts TB-001_2 A 'Rivet Nut' is a one piece fastener installed 'blind' from Table 1. Specifications one side of the machine body/framework. The rivet nut 4- Rivet Nut Rivet Nut Material Rivet Drill A is compressed so that a section of its shank forms an Thread...
Page 128 Section B - Body & Framework Fasteners Rivet Nuts Fitting Procedure (smooth bulge) seating itself against the body/ framework 7-E. Drill a hole in the machine body/framework where the Note: The thread of the rivet nut must not be stripped, take rivet nut is to be fitted.
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Page 130 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 132 Section C - Electrics Contents Page No. Technical Data General Electrical Data ................C - 1 Light Bulbs ..................C - 1 Sensing Switches ................... C - 2 Test Methods Using a Multimeter .................. C - 3 Measuring DC Voltage ..............C - 4 Measuring Resistance ...............
Page 133 Section C - Electrics Contents Contents Page No. Dismantling and Assembly ..............C - 50 Dismantling ..................C - 50 Servicing ..................C - 51 Assembling ..................C - 51 C - ii C - ii...
Page 134 Section C - Electrics Technical Data General Electrical Data System Type 12 Volts, negative earth Battery up to machine number 680579 Cold Crank Amps for 1 minute to 1.4 VPC at -18 °C (0 °F) 420 to 585 according to battery type Reserve capacity (minutes) for 25 Amp load 170 to 230 according to battery type Battery from machine number 680580...
Page 135 Section C - Electrics Technical Data Sensing Switches Sensing Switches Transmission Charge Pressure Switch. Normally closed, opens at 2-3.4 bar (30-50 lbf/in ) falling. Transmission Oil Temperature Switch. Normally open, closes at 107-113 °C (225-235 °F) rising. Reverse Alarm Pressure Switches. Normally open, closes at 7 bar (100 lbf/in ) rising.
Page 136 Section C - Electrics Test Methods Using a Multimeter TC-002 In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter.
Page 137 Section C - Electrics Test Methods Using a Multimeter Measuring Resistance Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket Make sure there is no power to the part of the circuit is also marked by a "-", or "E"...
Page 138 Section C - Electrics Test Methods Using a Multimeter Measuring Continuity Measuring Frequency Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of you are checking for continuity. measuring frequency, therefore a Fluke 85 digital multimeter must be used.
Page 139 Section C - Electrics Test Methods Using a Multimeter Testing a Diode or a Diode Wire c On an analogue meter. Select the Ohms 1000s (1k) range. A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The Connect the black probe to the end of the diode is sealed in heatshrink sleeving.
Page 140 Section C - Electrics Service Procedures Battery TC-001_3 Maintenance WARNING Batteries give off an explosive gas. Do not smoke To ensure that the battery provides optimum performance when handling or working on the battery. Keep the the following steps should be observed: battery away from sparks and flames.
Page 141 Section C - Electrics Service Procedures Battery GETS ONTO YOUR SKIN Set the CHECK/LOAD switch 7-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. Set the CHECK/LOAD switch 7-A to LOAD and hold down for 5-10 seconds until the meter reading 5-3-4-3_1...
Page 142 Section C - Electrics Service Procedures Battery Specific Gravity Testing Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. The specific gravity of the electrolyte gives an idea of the state of charge of the battery.
Page 143 Section C - Electrics Service Procedures Alternator Alternator TC-006 General Description Charging Circuit Test The alternator is a three phase generator having a rotating Ensure that all battery and alternator connections are field winding and static power windings. in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis When the start switch is turned on, current from the battery and engine.
Page 144 Section C - Electrics Service Procedures Alternator Alternator Charging Test Fig 8. Check 2 Note: The following checks should be made using an analogue (moving pointer) type meter. Stop the engine and turn the starter switch to OFF. Fig 10. Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'.
Page 145 Section C - Electrics Service Procedures Alternator Faults d, e, and f may be checked only by removing AVO 2002 – Red lead to volts (middle) socket on and dismantling the alternator for further testing. meter. – Black lead to negative on meter. –...
Page 146 Section C - Electrics Service Procedures Starting Circuit Test Starting Circuit Test Before carrying out the voltmeter tests, check that the Connect the voltmeter between the battery negative battery is in good condition and fully charged. Ensure that and starter earth connection B. The reading in the all connections are clean and tight.
Page 147 Section C - Electrics Problem Solving Symptom Possible cause Engine will not turn over Check state of charge and voltage of battery Check integrity of 80 amp primary fuse Check battery leads are tightly fastened Ensure High-flow system (if fitted) is switched off Check connections on ignition switch Check connections on neutral start relay Check connection on starter motor solenoid...
Page 148 Section C - Electrics Problem Solving Symptom Possible cause Listen to relay to see if it clicks when the horn button is pressed Check relay connections Check horn connections Front work lights will not operate Ensure ignition switch is on Check fuse A5 (20 amp) Does small bar on switch illuminate when the switch is on? If so, check bulbs in work lights...
Page 149 Section C - Electrics Circuit Diagrams Circuit Diagrams K Fig 12. ( T C-18) Hazard Switch Flasher Unit K Fig 13. ( T C-19) Indicator/Attachment Switch Main Components High-Flow Hydraulics Solenoid Valve High-Flow Hydraulics Switch Ignition Relay 1 Battery Ignition Relay 2 Starter Switch Heater Blower Switch Neutral Start Relay...
Page 150 Section C - Electrics Circuit Diagrams Lamps Quickhitch Switch Power Management Control Power Management ECU Alternator Warning Power Management Reset Water Temperature Warning Dump Valve Solenoid Hydraulic Oil Temperature Warning Proportional Attachment Control Switch Engine Oil Pressure Warning Proportional Attachment Control Voltage Air Cleaner Warning Regulator Charge Pump Pressure...
Page 151 Section C - Electrics Circuit Diagrams Fig 12. Circuit Diagram Sheet 1 C - 18 C - 18 9803-9450-1...
Page 152 Section C - Electrics Circuit Diagrams 600AB HEATER SWITCH 106R 106R 600EB SLOW 102A 600BH 600GR 600AC 800B FAST HEATER MOTOR 106AT FUSE A10 AIR CON SWITCH SWITCH ONLY FITTED WITH AIR/CON. 102C 3 SPEED FAN SWITCH 6A SLOW, 9A MED, 14A FAST 600AD AIR CON EVAP EARTH 800A...
Page 153 B-819 9/371. The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. 9/371 The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
Page 154 Section C - Electrics Harness Data Wire and Harness Number Identification Wire Numbers and Functions Wires 800-999 These numbers are reserved for switched supplies to Wires 000-199 electrical loads, i.e. to lights, etc. These numbers are reserved for ignition feeds, heater start Wires In Splices circuits and start circuits.
Page 155 Section C - Electrics Harness Data Harness Structure Harness Structure The diagram K Fig 16. ( T C-22) shows how the separate Optional harnesses are shown in dotted line. The item optional harnesses connect into either the standard numbers on the diagram relate to the item numbers in the mainframe harness or the cab roof/panel harness.
Page 156 Section C - Electrics Harness Data Drawings and Interconnection Drawings and Interconnection Harnesses Table 4. Harness No. Issue Remarks Drawing Mainframe Harness 721/12434 Sheet 1 K Fig 17. ( T C-24) Sheet 2 K Fig 18. ( T C-25) Sheet 3 K Fig 19.
Page 157 721/12434 issue 1, sheet 1 Fig 17. Mainframe Harness Sheet 1 K Fig 18. ( T C-25)
Page 158 721/12434 issue 1, sheet 2 Fig 18. Mainframe Harness Sheet 2 K Fig 19. ( T C-26)
Page 159 721/12434 issue 1, sheet 3 Fig 19. Mainframe Harness Sheet 3 K Fig 20. ( T C-27)
Page 160 721/12434 issue 1, sheet 4 Fig 20. Mainframe Harness Sheet 4 K Fig 21. ( T C-28)
Page 161 721/12434 issue 1, sheet 5 Fig 21. Mainframe Harness Sheet 5 K Fig 22. ( T C-29)
Page 162 721/12434 issue 1, sheet 6 Fig 22. Mainframe Harness Sheet 6 K Fig 23. ( T C-30)
Page 163 721/12434 issue 1, sheet 7 Fig 23. Mainframe Harness Sheet 7...
Page 164 721/12223 issue 3, sheet 1 Fig 24. Engine Harness Sheet 1 K Fig 25. ( T C-32)
Page 165 721/12223 issue 3, sheet 2 Fig 25. Engine Harness Sheet 2...
Page 166 721/12224 issue 5, sheet 1 Fig 26. Cab Roof Panel Harness Sheet 1 K Fig 27. ( T C-34)
Page 167 721/12224 issue 5, sheet 2 Fig 27. Cab Roof Panel Harness Sheet 2...
Page 168 721/12225 issue 2, sheet 1 Fig 28. Front Work Lights Harness Sheet 1...
Page 169 721/12226 issue 2, sheet 1 Fig 29. Head Lights Harness Sheet 1...
Page 170 721/12229 issue 2, sheet 1 Fig 30. Left Hand Front Side Light Harness Sheet 1...
Page 171 721/10752 issue 3, sheet 1 Fig 31. Right Hand Side Light Harness Sheet 1...
Page 172 721/10790 issue 4, sheet 1 Fig 32. Left Hand Bonnet Side Light Harness Sheet 1...
Page 173 721/12230 issue 2, sheet 1 Fig 33. Front Wash/Wipe Harness Sheet 1...
Page 174 721/12231 issue 2, sheet 1 Fig 34. Heater and Air Conditioning Harness Sheet 1...
Page 175 721/12242 issue 2, sheet 1 Fig 35. Heater (only) Harness Sheet 1...
Page 176 721/12227 issue 4, sheet 1 Fig 36. Instrument Panel Harness Sheet 1 K Fig 37. ( T C-44)
Page 177 721/12227 issue 4, sheet 2 Fig 37. Instrument Panel Harness Sheet 2...
Page 178 721/12307 issue 1, sheet 1 Fig 38. Attachment Changeover Solenoid Harness Sheet 1...
Page 179 Section C - Electrics Alternator Removal and Replacement TC-008 Removal Disconnect cables from rear of alternator, remove bolts 39- A, 39-B and 39-C and withdraw unit from machine. Fig 40. Replacement Replacement is the reversal of Removal. Set the fan belt tension. See Adjusting the Fan Belt Tension, Section 3.
Page 180 Section C - Electrics Alternator Dismantling and Assembling Dismantling and Assembling Fig 41. Dismantling Remove nuts and washers 5, bolts 6 and nuts 7. Remove slip ring and bracket 8. Remove suppressor 2 (if fitted) by removing nut 1 and Carefully remove rectifier 10 and stator 11 as an disconnecting lead E from terminal F.
Page 181 Section C - Electrics Alternator Dismantling and Assembling Check the rotor poles and the inner faces of the stator for signs of rubbing, which indicates worn bearings. The drive end bearing is part of bracket 17 and cannot be removed separately.
Page 182 Section C - Electrics Starter Motor Removal and Replacement Disconnect cables and remove battery. Remove cables from main starter terminal and solenoid terminal. Unscrew three securing nuts and remove starter. Replace by reversing the removal sequence. C - 49 C - 49 9803-9450-1...
Page 183 Section C - Electrics Starter Motor Dismantling and Assembly Dismantling and Assembly Fig 42. Dismantling Using a slotted steel tube, displace ring 23 to permit withdrawal of ring 22. Note: Dismantle only to item 34 unless the field windings Allow brake shoes 28 to remain in the end plate 11 unless are to be renewed.
Page 184 Smear drive shaft splines and operating collar bearing Check the field windings for open circuits by connecting an surface with JCB MPL Grease before assembly. Assemble ohmmeter (0 to 100 ohms) between the stud terminal B operating fork 19 with curved face toward the armature.
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Page 186 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 188 Section D - Controls Contents Page No. Manual Controls ..................D - 1 Dismantling and Assembly ..............D - 1 Manual Control Linkage - Foot Operated Loader ......D - 2 D - i D - i...
Page 189 Section D - Controls Contents Page No. D - ii D - ii...
Page 190 Dismantling and assembly procedures are straightforward and require no specific instructions other than the following: Renew worn parts as required. Lubricate all moving parts during assembly. Secure tension pins using JCB Retainer (High Strength). D - 1 D - 1 9803-9450-1...
Page 191 Section D - Controls Manual Controls Manual Control Linkage - Foot Operated Loader Fig 1. D - 2 D - 2 9803-9450-1...
Page 192 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 193 Section E - Hydraulics Page left intentionally blank E - 0 E - 0 9803/9450-2...
Page 194 Section E - Hydraulics Contents Page No. Technical Data General Data ..................E - 1 Loader Pump - Standard (P3) ............E - 1 Loader Pump - High-Flow (P3 and P5) ..........E - 1 Charge Pump (P4) ................E - 1 Relief Valve Operating Pressures ............
Page 195 Section E - Hydraulics Contents Contents Page No. Fault Finding Hydrostatic Transmission ..............E - 30 Checking for Faulty Pump or Motor ..........E - 33 Checking Wheel Speed ..............E - 35 Machine Veers to One Side when Travelling ........E - 37 Transmission Pump Neutral Adjustment .........
Page 196 Section E - Hydraulics Contents Contents Page No. Loader Pumps Typical Loader Pump ................E - 75 Removal ..................E - 75 Replacement ................... E - 75 Loader Pump - Standard Machines ............E - 76 Dismantling and Assembly .............. E - 76 Loader Pump - High-flow Machines .............
Page 197 New piston head fitted to a pre-drilled piston rod ......E - 115 New piston rod fitted to a pre-drilled piston head ......E - 115 JCB Ram Sealing Procedure ............E - 117 Servo Joysticks Removal and Replacement ..............E - 119 Removal ..................
Page 198 Section E - Hydraulics Technical Data General Data Note: System Cleanliness is to be to ISO 16/13 K Hydraulic Contamination ( T E-57) Loader Pump - Standard (P3) Type Single Gear Maximum flow at 2800 rev/min and 205 bar (2975 lbf/in 67.6 l/min (14.8 UK gal/min, 17.8 US gal/min) Loader Pump - High-Flow (P3 and P5) Type...
Page 199 Section E - Hydraulics Technical Data General Data Transmission Pump Type Tandem axial piston Series 42 Displacement 39 cc/rev (2.4 in /rev) Control Servo non-feedback proportional. Charge Pressure (oil temperature at 50° C) variable with 17 - 18 bar (246 - 261 lbf/in ) at engine idle engine speed 25 - 27 bar (362 - 391 lbf/in...
Page 200 Section E - Hydraulics Technical Data General Data Self Level Valve (optional) Type Solenoid controlled in line, adjustable split flow, level to lift only Filters Type High Pressure Spin - On Main Hydraulic Charge pressure filtration Main Return Return oil filtration Rams Dimensions Bore...
Page 201 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols TE-001 General (Basic and Functional Symbols) Table 2. Rams Complex hydraulic components and circuits can be Single acting described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.
Page 202 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Throttling orifice - normally Used to enclose several closed valves indicating they are supplied as one unit 3-Position, 4-port spring Throttling orifice - normally centered pilot operated valve open 3-position, 6-port spring centered pilot operated valve...
Page 203 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed Reservoir - return line below fluid level Pilot control Drain lines Header tank Flexible pipe Pressure sealed tank Line junction Accumulator Crossing lines...
Page 204 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding Rotating shaft - one direction Solenoid two windings Rotating shaft - two directions Detent Electric motor operated Locking device Internal pressure pilot operated Over centre device External pressure pilot...
Page 205 K Fig 2. ( T E-8) - In circuit diagrams the pipework is usually shown connected to the box which represents the Three typical JCB style spools are known as 'D' spools, 'F' unoperated condition. (Hydraulic circuit diagrams are spools and 'N' spools.
Page 206 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Example of Schematic Circuit Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages Example Circuit Key have been arranged into a simple schematic circuit. K Fig 7.
Page 207 Section E - Hydraulics Operation Description Neutral Circuits Neutral Circuits The illustrations show the major components of the show the neutral circuit flow. Refer also to the appropriate hydraulic system in their approximate relative positions as schematic circuit. viewed from the left hand side of the machine. The arrows Standard Machines C045470 Fig 8.
Page 208 Section E - Hydraulics Operation Description Neutral Circuits High-flow Machines which feeds the attachment service. Oil returns to tank T from control valve 9 via filter F2 and cooler C. Oil is drawn from tank T by gear pumps P3, P4 and P5 via Charge pump P4 which is engine driven, delivers suction strainer S.
Page 209 Section E - Hydraulics Operation Description Neutral Circuits Loader Circuit Transmission Circuit The standard servo loader valve block consists of two The transmission pump consists of two axial piston pumps hydraulic servo operated spools controlling loader arm lift mounted in-line and driven through a flexible coupling from and carriage tilt functions and a third servo operated the back of the engine.
Page 210 Section E - Hydraulics Operation Description Transmission Pump Operation Transmission Pump Operation Charge Pressure The transmission pump consists of two pump units, one for each drive motor, mounted in tandem on a common drive shaft which is driven by the engine. The illustration below The charge pressure (and hence the drive system servo shows one typical pump unit.
Page 211 Section E - Hydraulics Operation Description Transmission Pump Operation Fig 10. Fig 11. E - 14 E - 14 9803-9450-2...
Page 212 Section E - Hydraulics Operation Description Transmission Motor Operation Transmission Motor Operation The basic components of the transmission motor are the Table 8. Key cylinder block containing eight radially positioned pistons Shuttle spool with attached rollers working inside a circular cam, the 2 Speed spool distributor, shuttle valve and flushing valve.
Page 213 Section E - Hydraulics Operation Description Servo Transmission Operation Servo Transmission Operation Neutral is blocked by the spools 12a, 12b, 12c and 12d and therefore no servo pressure is applied to operate the swash plates of pumps P1 and P2. K Fig 13.
Page 214 Section E - Hydraulics Operation Description Servo Transmission Operation Forward Pressure is also fed to the motor shuttle valves M1a and M2a causing them to move down and connect the motor relief valves to the return side of the loop circuits. K Fig 14.
Page 215 Section E - Hydraulics Operation Description Servo Transmission Operation Reverse Pressure is also fed to the motor shuttle valves M1a and M2a causing them to move up and connect the motor relief valves to the return side of the loop circuits. K Fig 15.
Page 216 Section E - Hydraulics Operation Description Servo Transmission Operation Right Spin Turn In the case of a left spin turn, servo spool 12b is selected and the pumps and motors operate in the opposite direction. K Fig 16. ( T E-19) Pressure is also fed to the motor shuttle valves M1a and When the joystick 12 is moved to select right spin turn, M2a causing them to move and connect the motor relief...
Page 217 Section E - Hydraulics Operation Description Loader Valve Operation Loader Valve Operation Fig 17. (X E-21) Fig 18. (X E-22) show a servo operated valve but the description also applies to manual valves. Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral...
Page 218 Section E - Hydraulics Operation Description Loader Valve Operation Neutral Circuit Fig 17. Fig 17. (X E-21) shows the oil flow through the valve when no service is selected. Oil from the gear pump enters the valve through the inlet port, flows through the galleries around the spool centres and exits at the exhaust port where it returns to the tank.
Page 219 Section E - Hydraulics Operation Description Loader Valve Operation Shovel Tilt Fig 18. Fig 18. (X E-22) shows the shovel tilt service selected. On Oil returning from the opposite end of the tilt ram enters the servo machines, when the joystick is moved servo oil is valve block and flows past spool 9c into the exhaust gallery supplied to the appropriate end of the tilt spool 9c which and back to tank.
Page 220 Section E - Hydraulics Operation Description Loader Valve Operation Fig 19. (X E-23) Fig 20. (X E-24) show a manually operated valve but the description also applies to servo valves. Lift Arm Raise Fig 19. Fig 19. (X E-23) shows lift arm raise selected. On servo Oil returning from the opposite end of the lift ram enters the machines, when the joystick is moved servo oil is supplied valve block and flows past spool 8b but this time enters the...
Page 221 Section E - Hydraulics Operation Description Loader Valve Operation Lift Arm Lower Fig 20. Fig 20. (X E-24) shows lift arm lower selected. On servo machines, when the joystick is moved servo oil is supplied to the appropriate end of the tilt spool 8b which moves to select the lower service.
Page 222 Section E - Hydraulics Operation Description Self Level Valve Self Level Valve The optional self level valve diverts a small amount of oil to the Quickhitch tilt ram to give self levelling of the Quickhitch as the loader arm is raised. A solenoid valve allows the self level circuit to be switched in or out as required by the operator.
Page 223 Section E - Hydraulics Operation Description Self Level Valve Tilt Ram Fully Extended Loader Arm Lower K Fig 22. ( T E-26) K Fig 23. ( T E-26) If the Quickhitch tilt ram 5 reaches the end of its stroke When the loader arm spool 9B is selected to ‘lower’, oil during the self level cycle, or the operator selects the tilt flows to port ‘B’...
Page 224 Section E - Hydraulics Operation Description Self Level Valve Tilt Ram Extend Tilt Ram Retract K Fig 24. ( T E-27) K Fig 25. ( T E-27) When the Quickhitch tilt spool 9C is selected to ‘dump’, oil When the Quickhitch tilt spool 9C is selected to ‘crowd’, oil is directed from the loader valve 9 to the head side of the flow is directed to the rod side of the tilt ram 5.
Page 225 Section E - Hydraulics Operation Description Power Management System (P.M.S.) Power Management System (P.M.S.) ECU4 Fig 26. E - 28 E - 28 9803-9450-2...
Page 226 Section E - Hydraulics Operation Description Power Management System (P.M.S.) The Power Management System (PMS) is designed to the control pressure supplied by the PMS dump valve for reduce instances of engine stalling during operations any given engine speed. involving high transmission loads and to enhance transmission control when operating attachments such as During normal loading operations, knob D should be set at patch planers.
Page 227 Section E - Hydraulics Fault Finding Hydrostatic Transmission Before carrying out any problem solving or any tests on the Fluids, Lubricants and Capacities) and that the system machine, make sure that the hydraulic system is filled to is at the correct working temperature ((50 °C, 122 °F). the correct level with the correct grade of hydraulic oil (see PROBLEM CAUSE...
Page 228 Section E - Hydraulics Fault Finding Hydrostatic Transmission Key to Cause Remedy Page Ref. No oil in hydrostatic system Check supply of oil to pump. Section 3 Isolator bar or arm rest not in correct Ensure isolator bar and arm rest are in operating Section C position position, check electrical wiring and switch as...
Page 229 Section E - Hydraulics Fault Finding Hydrostatic Transmission Key to Cause Remedy Page Ref. Feed hose failure Check motor feed hoses. No hydraulic feed to joystick Check for feed to joystick. K Checking the Joystick Hydraulic Lines ( T E-42) No hydraulic feed from joystick to Check for feed from joystick to pump.
Page 230 Section E - Hydraulics Fault Finding Hydrostatic Transmission Checking for Faulty Pump or Motor Fig 27. If the transmission operates or is faulty on one side only Proceed as follows: then swop the motor feed hoses to check if the fault is with the pump or motor.
Page 231 Section E - Hydraulics Fault Finding Hydrostatic Transmission WARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid.
Page 232 Section E - Hydraulics Fault Finding Hydrostatic Transmission Checking Wheel Speed procedure on Checking for Faulty Pump or Motor (X E-33) to determine which is faulty. The pump output and general efficiency of the drive Following this procedure, further small adjustments may system may be checked by raising the machine off the be required to achieve correct straight line travel ground and checking the wheel speeds.
Page 233 Section E - Hydraulics Fault Finding Hydrostatic Transmission "" Fig 28. E - 36 E - 36 9803-9450-2...
Page 234 Section E - Hydraulics Fault Finding Hydrostatic Transmission 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. Check tyre pressures and The pressure of one tyre may be low or one or both tyres on one side of the condition machine may be new and the other tyres worn.
Page 235 Section E - Hydraulics Fault Finding Hydrostatic Transmission Transmission Pump Neutral Adjustment This procedure may be carried out if the machine creeps when the drive control is in the neutral position. This fault may be due to an incorrect neutral setting of the servo piston.
Page 236 Section E - Hydraulics Fault Finding Hydrostatic Transmission Fig 29. E - 39 E - 39 9803-9450-2...
Page 237 Section E - Hydraulics Fault Finding Hydrostatic Transmission 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 238 Section E - Hydraulics Fault Finding Hydrostatic Transmission Pump Main Relief Pressure Test Points Testing Main Relief Valves The upper illustration shows the right hand side of the Whilst carrying out this test make sure the area around the pump, the lower illustration shows the left hand side of the machine is clear of personnel.
Page 239 Section E - Hydraulics Fault Finding Hydrostatic Transmission Checking the Joystick Hydraulic Lines The pressure gauge should show transmission pump charge pressure with full joystick travel (K General Data ( T E-1) If the machine does not respond to joystick movements, check the hydraulic supply to and from the joystick as If any readings are not correct, check the hoses for follows:...
Page 240 Section E - Hydraulics Fault Finding Loader Circuit Loader Circuit The purpose of this section is to help you trace hydraulic – Before you begin problem solving, read the Safety problems to a faulty unit (valve, actuator, ram etc.). Once Information at the beginning of this manual.
Page 241 Section E - Hydraulics Fault Finding Loader Circuit Key to Cause Remedy Page Ref. Insufficient hydraulic fluid. Check for leaks and top up as required. Hydraulic leaks in system. Check hoses, replace as required. Main relief valve (MRV) setting Check and adjust as required. K Loader Main Relief incorrect.
Page 242 Section E - Hydraulics Fault Finding Loader Circuit Key to Cause Remedy Page Ref. Make sure that associated load hold check valve is operating. On servo machines, check operation of joystick and feed hoses. On manual machines, check that control lever and associated linkage is operating the spool, rectify as required.
Page 243 Section E - Hydraulics Fault Finding Levelling Circuit Levelling Circuit Symptoms Possible Causes Countermeasures Boom delay at start of self-level Air in system Cycle boom and bucket slowly to rid or unstable self-level system of air Loaded bucket dumps or Unloading spool is leaking Remove and inspect unloading spool for raises when control valve is in...
Page 244 Section E - Hydraulics Fault Finding High-flow Circuit High-flow Circuit In the event of poor attachment performance or hydraulic Table 10. Flow Rates overheating when using the High-flow circuit, the following Pressure L/min (UK gal/min) [US gal/min] procedure should be followed to ensure optimum machine Max.
Page 245 Section E - Hydraulics Fault Finding High-flow Circuit 340290 Fig 36. E - 48 E - 48 9803-9450-2...
Page 246 Section E - Hydraulics Fault Finding High-flow Circuit Fig 37. E - 49 E - 49 9803-9450-2...
Page 247 Section E - Hydraulics Fault Finding Power Management System (P.M.S.) Power Management System (P.M.S.) Warning Light Indications Fig 38. When the ignition is turned on the warning light G should come on to indicate that the PMS is live. When the engine Fig 39.
Page 248 Section E - Hydraulics Fault Finding Power Management System (P.M.S.) (290 lb/in ) when fully anti-clockwise to10 bar (145 lb/ ) when fully clockwise. Fault Tracing Table 12. Fault Possible Cause Action Warning light flashes Blink Signal from alternator W terminal absent Check alternator drive belt tension and Code 1 K Blink...
Page 249 Section E - Hydraulics Fault Finding Power Management System (P.M.S.) Fault Possible Cause Action Connection from alternator, wire number 412 (pin 7). Earth, wire number 600AF (pin 1). Check fuse B5. Check wiring to warning light. If all above are OK, fit new ECU 4. Low tractive effort at high Sensitivity control set to minimum (when Adjust sensitivity control.
Page 250 Section E - Hydraulics Fault Finding General General Bleeding the Hydraulic System It may be necessary to bleed the hydraulic system if major components have been removed. Air in the system will result in uneven loader operation. Make up a hose loop with two quick release connectors and connect across the two standard quick release couplings A on the machine.
Page 251 Circuit Diagrams Standard and High-flow Servo Machines Component Key Servo Cut-off Valve Accumulator Drive Servo Control Valve Lift Ram Fig 42. (X E-55) Forward Float Valve (Optional) Left Levelling Valve (Optional) Cooler Reverse Tilt Ram Charge Filter Right Dump Valve Loader Filter Shuttle Valves Brake Valve...
Page 252 FEED LHS N/S MOTOR INTO B=FWD FEED LHS N/S MOTOR INTO A=REV FEED RHS O/S MOTOR INTO B=REV FEED RHS O/S MOTOR INTO A=FWD DRIVE MOTOR TRANSMISSION PUMP DRIVE MOTOR SERVO CONTROL VALVE LHS N/S RHS O/S REAR PUMP FRONT PUMP PLAN VIEW PLAN VIEW PUMP HUSCO VALVE...
Page 253 PUMP CASE OUT TRANSMISSION PUMP CASE OUT TRANSMISSION PUMP TRANSMISSION PUMP SERVO PORTS SERVO PORTS SERVO CUT-OFF DUMP VALVE PORT B VALVE PORT B Fig 45. Dual Controls Fig 43. JCB Servo Controls E - 56 E - 56 9803-9450-2...
Page 254 Section E - Hydraulics Service Procedures Hydraulic Contamination TE-002_2 Hydraulic Fluid Quality cleaning unit. K Fig 46. ( T E-57). General Bulletin 011 also refers. Construction machinery uses a large volume of fluid in the Procedure hydraulic system for power transmission, equipment lubrication, rust prevention and sealing.
Page 255 Section E - Hydraulics Service Procedures Hydraulic Contamination Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: –...
Page 256 Section E - Hydraulics Service Procedures Cleaning Operation Cleaning Operation The purpose of cleaning the hydraulic oil is to remove At low engine revs, operate the services slowly to contaminants of all types and sludge. extend the rams, this will expel the dirty oil from the rod side of the rams and new oil will be put into the Procedure head side.
Page 257 Section E - Hydraulics Pressure Testing Loader Main Relief Valve (M.R.V.) Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F) Remove the seat and seat base. Connect a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm pressure gauge to test connector A.
Page 258 Section E - Hydraulics Pressure Testing Loader Main Relief Valve (M.R.V.) Fig 48. E - 61 E - 61 9803-9450-2...
Page 259 Section E - Hydraulics Pressure Testing Transmission Charge Pressure Transmission Charge Pressure Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F). Stop engine. Connect a 0 - 40 bar (0 - 600 lb/in , 0 - 42 kg/cm ) pressure gauge into test point X1 at the hydraulic filter.
Page 260 Section E - Hydraulics Pressure Testing Power Management System (P.M.S.) Power Management System (P.M.S.) Calibration Procedure It is necessary to do this procedure if you have fitted a new P.MS. controller (E.C.U. 4) Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).
Page 261 Section E - Hydraulics Pressure Testing Power Management System (P.M.S.) Fig 53. On machines not fitted with sensitivity control F: a Remove front switch panel. 660A Fig 55. c Remove blanking plug from connector D K Fig 55. ( T E-64) (fed by wire numbers 144B, 509 and 600AH).
Page 262 Section E - Hydraulics Pressure Testing Power Management System (P.M.S.) Table 13. Start engine. If red light G does not go out, start Test Crankshaft Fan Speed Pressure procedure again from step 4. Speed Stage 1 1800 1980 10 bar (145 lb/in Stage 2 2400...
Page 263 Section E - Hydraulics Pressure Testing Power Management System (P.M.S.) To fit Sensitivity Control to Non High Locate the socket fed by wires 660 and 660A. Remove linking plug H from the socket. Fit blank 719/ Flow Machines 10101 in place of linking plug H. Fig 56.
Page 264 Section E - Hydraulics Transmission Pumps Removal and Replacement Removal Coat threads of flange bolts E with JCB Threadlocker and Sealer, fit and tighten to correct torque setting K Table 16. Torque Settings ( T E-68). Remove the seat plate and pump cover.
Page 265 Section E - Hydraulics Transmission Pumps Removal and Replacement Table 16. Torque Settings Item kgf m lbf ft 15.3 Motor feed hoses Motor feed 20.4 adapters Servo hoses Servo port adapters E - 68 E - 68 9803-9450-2...
Page 266 Section E - Hydraulics Transmission Pumps Removal and Replacement Fig 60. E - 69 E - 69 9803-9450-2...
Page 267 F is fitted to the groove in the bore. Fig 62. Coat threads of bolts C with JCB Threadlocker and Sealer and torque tighten to 23 Nm (17 lbf ft, 2.3 kgf m). Coat threads of capscrew D with JCB Retainer (High Strength) and torque tighten to 49 Nm (36 lbf ft, 5 kgf m).
Page 268 Section E - Hydraulics Transmission Pumps Dismantling and Assembly Dismantling and Assembly Fig 63. E - 71 E - 71 9803-9450-2...
Page 269 Section E - Hydraulics Transmission Pumps Dismantling and Assembly Slide seal carrier 2 over the shaft and press into Following a complete rebuild of this pump it is necessary position in the pump body recess. for it to be set up on a dynamic test jig. Because of this it is recommended that no dismantling work is carried out K Fig 63.
Page 270 Section E - Hydraulics Transmission Pumps Dismantling and Assembly Note: The conical spring must be correctly retained on the relief valve to ensure satisfactory pump operation. Refit plug 10 and torque tighten to 68 Nm (50 lbf ft). Charge Valve Dismantling and Assembly Mark the plug 17, locknut 16 and the pump body so as to approximately maintain the original adjustment.
Page 271 Section E - Hydraulics Transmission Pumps Start-Up Procedure Start-Up Procedure The following start-up procedure should always be Install a 0 - 40 bar (0 - 600 lbf/in , 0 - 42 kgf/cm ) pressure followed when starting up a new installation or when gauge in the pressure test point at the hydraulic filter.
Page 272 Section E - Hydraulics Loader Pumps Typical Loader Pump Removal Remove the seat plate and pump cover. Drain the hydraulic tank. Access to the hydraulic tank drain plug is through the chassis blanking plate X. Remove the blanking plate and place a suitable container beneath the machine to catch the oil.
Page 273 Section E - Hydraulics Loader Pumps Loader Pump - Standard Machines Loader Pump - Standard Machines Dismantling and Assembly Fig 67. The numerical sequence shown on the illustration is Renew the pump if the shaft diameter in the bush area is intended as a guide to dismantling K Fig 67.
Page 274 Section E - Hydraulics Loader Pumps Loader Pump - Standard Machines Assembly Renew all parts supplied in the seal kit. Retain the ‘O’ rings in their grooves with a little petroleum jelly. Fit seal 10 into cover 12 with open part of the ‘V’ section downwards.
Page 275 Section E - Hydraulics Loader Pumps Loader Pump - High-flow Machines Loader Pump - High-flow Machines Dismantling and Assembly 18 19 20 21 22 24 25 C044010 Fig 68. Inspection The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 68.
Page 276 Section E - Hydraulics Loader Pumps Loader Pump - High-flow Machines Renew the pump if the shaft diameter in the bush area is Place wear plate 8 on top of seal 11 and wear plate 18 on less than 22.17 mm (0.873 in) or if the gear width is less top of seal 21 with bronze face upwards.
Page 277 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Removal and Replacement Disconnect the hydraulic hoses from the motors A. Plug exposed connections. Remove capscrews B and withdraw motor complete with drive shaft. Important: Do not pick up the motor by the drive shaft as this can cause damage to the balance plate.
Page 278 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Dismantling 333710 ‹ › ﬁ ‚ ﬂ · ‡ ° 333720 £ ⁄ ) ¤ & 333740 & Fig 70. E - 81 E - 81 9803-9450-2...
Page 279 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Important: Do not pick up the motor by the drive shaft as Install poppet 30, spring 29 and dash pot 28 into shuttle this can cause damage to the balance plate 9. valve bore from valve plate side of end cap 17.
Page 280 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Fig 71. E - 83 E - 83 9803-9450-2...
Page 281 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Motor Bearing Housing Ensure mating surfaces of bearing housing and chain case are clean. Lightly lubricate a new ‘O’ ring with petroleum jelly and fit into the groove in the bearing housing. Removal and Replacement After replacement, torque tighten bolts A diagonally to 184 Removal...
Page 282 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Dismantling Note: The lower motor bearing housing is shown on the right hand side of the following illustrations. The upper housing is shown on the left hand side. Fig 73. Remove the four motor mounting capscrews A and Remove the spacer D from inside the drive spline separate the motor B from the bearing housing.
Page 283 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Fig 74. Remove the retaining ring E, washer F and spacers G from the motor end of the housing. E - 86 E - 86 9803-9450-2...
Page 284 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Fig 75. Using a press, push the shaft assembly H out through Remove quad seal K and back-up ring L from the the housing. Collect bearing cone J. groove in the bore of the housing. Assembly E - 87 E - 87...
Page 285 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Install a new back-up ring L into the housing bore Assemble the bearing cups into the housing bores followed by a new quad seal K. Make sure the seal is with tapers facing outward.
Page 286 Section E - Hydraulics Drive Motors Motors - Wheeled Machine Immediately after assembly of bearing cone J install K Fig 77. ( T E-89). If new bearings have been used shim G (if necessary), washer F and snap ring E it will be necessary to take a measurement as follows: Fig 77.
Page 287 Section E - Hydraulics Drive Motors Motors - Tracked Machine Motors - Tracked Machine Removal and Replacement 765120 Fig 79. E - 90 E - 90 9803-9450-2...
Page 288 Support the motor C with a sling and hoist. Remove the remaining bolt and lift the motor clear. Replacement Replacement is the reversal of the removal procedure. Apply JCB Threadlocker & Sealer to motor mounting bolts before fitting. Table 20. Torque Settings Item...
Page 289 Section E - Hydraulics Drive Motors Motors - Tracked Machine Brake Dismantling and Assembly 766560 Fig 80. The numerical sequence shown is a guide to dismantling. For assembly the sequence should be reversed. E - 92 E - 92 9803-9450-2...
Page 290 Drain the oil from the unit and disconnect the pipework Thoroughly degrease capscrews 10 then, after fitting from the brake housing 12. washers 11, apply JCB Threadlocker & Sealer to the threads. To maintain squareness, tighten capscrews in a All ‘O’ rings, sealing rings and gaskets removed during diametrically opposite pattern to the correct torque.
Page 291 Section E - Hydraulics Drive Motors Motors - Tracked Machine Table 21. Torque Settings To release distributor 28, drop the rear case 21 assembly from a height of approximately 8 cm (3 in) onto a wooden Item kgf m lbf ft surface.
Page 292 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 294 Section F - Transmission Contents Page No. Description Drive Train ....................F - 1 Tracked machines ................... F - 3 Tyres and Wheels Roadwheels ..................... F - 4 Removal ..................... F - 4 Replacement ..................F - 4 Wheel Hubs and Drive Shafts Wheel Hub Assembly (right hand) ............
Page 295 Section F - Transmission Contents Page No. F - ii F - ii...
Page 296 Section F - Transmission Description Drive Train Fig 1. The drive train consists of two hydraulic motors, four drive is mounted a double sprocket. The motor output shafts are chains, two right hand hub assemblies and two left hand splined into the drive shafts. drive shafts.
Page 297 Section F - Transmission Description Drive Train Adjustment for the chains is provided on the right hand side by rotation of the hub assemblies which alters the position of the sprockets. The left side chains are adjusted by repositioning the upper motor adapter housing which is mounted on slotted holes for this purpose.
Page 298 Section F - Transmission Description Tracked machines Tracked machines The drive train consists of left and right hand hydraulic motors, each mounted directly onto the track frame. Sprockets mounted on the output flanges of the motors transmit drive directly to the tracks (see Section J) F - 3 F - 3 9803-9450-1...
Page 299 Section F - Transmission Tyres and Wheels Roadwheels Removal WARNING 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. Ensure the other end is securely Slacken off the road wheel retaining nuts A, then raise and chocked.
Page 300 Section F - Transmission Wheel Hubs and Drive Shafts Wheel Hub Assembly (right hand) Fig 3. Removal Remove the nut B and pull the hub assembly out; remove the chain from the sprocket. Remove the hub assembly from the chassis. Remove and discard seal. It is assumed that roadwheels are removed and the machine is correctly supported.
Page 301 Section F - Transmission Wheel Hubs and Drive Shafts Wheel Hub Assembly (right hand) Torque tighten nut A and bolts B to 220 Nm (162 lbf ft, 22.4 kgf m). Refit cover plate C using a new gasket. Refill the chain case with the correct oil. F - 6 F - 6 9803-9450-1...
Page 302 Section F - Transmission Wheel Hubs and Drive Shafts Wheel Hub Assembly (right hand) Dismantling Fig 4. F - 7 F - 7 9803-9450-1...
Page 303 5 full revolutions to ensure that the bearings are fully seated then recheck and, if necessary, tighten stud C Lubricate outer bearing 7 and seal 8 with JCB Special HP further to 80 Nm (59 lbf ft, 8.2 kgf m).
Page 304 Section F - Transmission Wheel Hubs and Drive Shafts Wheel Hub Assembly (right hand) Check that the hub rotates freely by hand. Table 1. Torque Settings Item kgf m lbf ft 22.4 (1) Torque setting whilst checking Preload Fig 6. Position a dial gauge against the flat face of the sprocket as shown at D and zero the gauge.
Page 305 Section F - Transmission Wheel Hubs and Drive Shafts Drive Shaft Assembly (left hand) Drive Shaft Assembly (left hand) 10 11 Fig 7. F - 10 F - 10 9803-9450-1...
Page 306 Assemble the twine cutter, if previously removed, and tighten bolts 12 to the correct torque. It is assumed that roadwheels are removed and the Lubricate outer bearing 10 and seal 11 with JCB Special machine is correctly supported. HP Grease before assembly. Inner bearing 9 should be assembled without grease.
Page 307 Section F - Transmission Wheel Hubs and Drive Shafts Drive Shaft Assembly (left hand) remove the oil seal installer. Note that it may be necessary Part No. Thickness to gently tap the end of the shaft to release the installer. 242/00096 0.025 - 0.045 mm 823/10303...
Page 308 Section F - Transmission Drive Chains Removal and Replacement Removal It is assumed that roadwheels are removed and the machine is correctly supported. Drain the oil from the chain case (see Section 3) Remove the chain case access cover. Note: The rear chains must be released from the motor sprockets before the front chains can be removed.
Page 309 Section F - Transmission Drive Chains Removal and Replacement Fig 11. Starting with the rear chain, remove bolt D, washer E and Adjust the chains K Adjustment ( T F-15). preload washer F then withdraw sprocket G from shaft H. Refit the chaincase access cover using a new gasket.
Page 310 Section F - Transmission Drive Chains Removal and Replacement Adjustment mounting to give 10 mm (0.4 in) of slack on the opposite side of the chain at the midway point. Note: The drive chains are pre-tensioned during When the correct adjustment is achieved, tighten manufacture and do not require routine adjustment in locknuts B.
Page 311 Section F - Transmission Drive Chains Removal and Replacement Fig 13. F - 16 F - 16 9803-9460-1...
Page 312 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 314 Section G - Brakes Contents Page No. Moving a Disabled Machine Towing/Winching ..................G - 1 Preparation for Towing/Winching ............G - 1 G - i G - i...
Page 315 Section G - Brakes Contents Page No. G - ii G - ii...
Page 316 Section G - Brakes Moving a Disabled Machine Towing/Winching It is only possible to tow or winch the JCB Skid Steer CAUTION Loader very slowly for a short distance in a straight line. Do not loosen the relief valves by more than four turns Do not tow a machine unless there is no alternative.
Page 317 Section G - Brakes Moving a Disabled Machine Towing/Winching Page left intentionally blank G - 2 G - 2 9803-9450-1...
Page 318 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 319 Section J - Tracks Page left intentionally blank J - 0 J - 0 9803/9450-1...
Page 320 Section J - Tracks Contents Page No. Basic System and Operation Description ....................J - 1 Track Damage Types of Rubber Track Damage .............. J - 3 Track Repair Recommended Repair Procedures ............J - 13 Track Removal and Replacement Removal ....................
Page 321 Section J - Tracks Contents Page No. J - ii J - ii...
Page 322 Section J - Tracks Basic System and Operation Description Note: This section applies only to tracked versions of the machine. Running Gear Components The track assemblies are mounted on each side of the machine chassis in place of the wheel hubs. Fig 1.
Page 323 Section J - Tracks Basic System and Operation Description Track Construction Track Serial Number Location and Production Date The structure of the rubber track consists of core bar H and steel cord J encased in the rubber track K. The core bar The track is embossed with the production date and serial and steel cord give the track its internal strength and number as shown in...
Page 324 Section J - Tracks Track Damage Types of Rubber Track Damage Rubber tracks used numerous operating Refer to the quick reference table below, then to the environments/ applications, it is therefore possible that corresponding paragraph for illustrated examples of the damage may occur to the track.
Page 325 Section J - Tracks Track Damage Types of Rubber Track Damage Core Bars - Separation Core Bars - Breaking Breaking in the middle Cause: Low track tension - the core bars are likely to hit the Cause: running gear components and lead to separation from the track Excessive track tension together with a shock load, for example, climbing pavement edges.
Page 326 The teeth of the sprocket are worn (hook shaped). Operating environment is extremely abrasive Prevention: Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition. Replace sprocket. When new tracks are fitted, the sprockets should always be checked (and renewed if Fig 6.
Page 327 The steel cord has been exposed and rusted. Prevention: Prevention: Clean the tracks with fresh water after operation. Make sure that the sprocket is genuine JCB, ensure Make sure that the visible metallic components of the sprocket is in good condition. track are greased.
Page 328 The sprocket is not appropriate for the track. the ground surface in rough terrain, e.g. demolition sites, rocky ground etc. Prevention: Check the tension regularly. Make sure that the sprocket is genuine JCB, ensure sprocket is in good condition. Fig 11. Additional Notes: Fig 10.
Page 329 Section J - Tracks Track Damage Types of Rubber Track Damage Steel Cord - Sticking Out Additional Notes: Individual strands of steel cord sticking out of the track Cause: does not necessarily mean the track needs to be replaced. Individual strands can be cut off (the number of steel cord Strands of the steel cord may sometimes stick out of strands is always over specified), however exposed the rubber track.
Page 330 Section J - Tracks Track Damage Types of Rubber Track Damage Outer Track Rubber - Tearing/Cuts Outer Track Rubber - Fast Abrasion Cause: Cause: Cuts on the lug are often due to particularly sharp Sharp driving on hard and abrasive surfaces, for materials such as stones, the problem is particularly example concrete, asphalt etc.
Page 331 Section J - Tracks Track Damage Types of Rubber Track Damage Outer Track Rubber - Cracks Outer Track Rubber - Longitudinal Cracks Cause: Cause: Bending fatigue of the rubber after excessive use. The edges of the rubber track are often deformed Long storage (a few months) outside in the sunlight.
Page 332 Section J - Tracks Track Damage Types of Rubber Track Damage Inner Track Rubber - Tearing/Cuts Fig 18. Cause: Stones and sharp material can tear the rubber at the edges of the track. Driving close to pavement edges and ridges - causing the edges to be forcefully bent against the track frame.
Page 333 Prevention: Prevention: Make sure that the sprocket is genuine JCB, ensure Check the tension regularly. sprocket is in good condition. Do not let the machine sit too long in the same Check the track tension regularly (as recommended position when operating in these conditions.
Page 334 Section J - Tracks Track Repair Recommended Repair Procedures Minor cuts which occur between the lugs can be repaired with a suitable repair kit. Cuts no longer than 30mm and no deeper than 10mm do not need to be repaired. Cuts beyond these dimensions should be repaired as detailed.
Page 335 Section J - Tracks Track Repair Recommended Repair Procedures Fig 24. Ensure that the adhesive applied in step 3 has completely dried and then apply another adhesive layer. When the second adhesive layer is almost dry (sticky to the touch) the rubber compound should be firmly applied to the cut.
Page 336 Section J - Tracks Track Removal and Replacement Removal Position machine on a firm, level surface. Raise the machine on the side to be worked on as follows: a Place a block of wood under one end of the shovel and fully lower and tilt the shovel onto the block so as to raise the front of the machine.
Page 337 Section J - Tracks Track Removal and Replacement Removal Fig 25. J - 16 J - 16 9803-9450-1...
Page 338 Section J - Tracks Track Removal and Replacement Replacement Replacement Position the track so that it locates under the bottom rollers and around the front and rear idler wheels. Position a support under the track to take up the sag at the bottom.
Page 339 Section J - Tracks Idler Wheels and Rollers Front Idler Wheel and Recoil Unit Idler Wheels and Rollers Front Idler Wheel and Recoil Unit Removal These components can be removed without removing the track frame from the machine. Remove track (see K Removal ( T J-15)).
Page 340 Idler wheel end float should be 0.2 - 1.2 mm (0.008 - 0.047 in). Fill with 57cc of EP60W/90 oil though the plug hole. Coat threads of plug 10 with JCB Threadlocker & Sealer before fitting. Fig 27. Clean the assembly thoroughly before attempting to dismantle.
Page 341 ‘O’ rings 3. Replacement is a reversal of the removal procedure. Lift off bracket 4. Apply JCB Threadlocker & Sealer to threads of securing Remove idler wheel assembly 5. bolts and tighten to 395 Nm (291 lbf ft; 40 kgf m).
Page 342 Idler wheel end float should be 0.2 - 1.2 mm (0.008 - 0.047 in). Fill with 57cc of EP60W/90 oil though the plug hole. Coat threads of plug 8 with JCB Threadlocker & Sealer before fitting. J - 21 J - 21...
Page 343 Note: It may be necessary to open out the track frame, using a suitable jack, to allow the roller to slide into position. Apply JCB Threadlocker & Sealer to threads of securing bolts and tighten to 220 Nm (162 lbf ft; 22 kgf m). J - 22...
Page 344 Dismantling Roller end float should be 0.12 - 1.37 mm (0.005 - 0.053 in). Fill with 165cc of EP60W/90 oil though the plug hole. Coat threads of plug 8 with JCB Threadlocker & Sealer before fitting. 773060 Fig 31. Clean the assembly thoroughly before attempting to dismantle.
Page 345 Section J - Tracks Track Frame Assembly Removal 765200 Fig 32. Raise and support the machine and remove the track CAUTION (see K Removal ( T J-15)). Do not pull the frame too far away otherwise the hoses Disconnect the motor feed and return hoses having will rip off.
Page 346 Section J - Tracks Track Frame Assembly Replacement Replacement 765200 Fig 33. Replacement is a reversal of the removal procedure. Tighten front and rear mounting bolts to 184 Nm (136 lbf ft, 18.8 kgf m). J - 25 J - 25 9803-9450-1...
Page 347 Section J - Tracks Track Frame Assembly Replacement Page left intentionally blank J - 26 J - 26 9803-9450-1...
Page 348 Customer Support Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
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Page 350 Section K - Engine Contents Page No. Specification Technical Data ..................K - 1 Removal and Replacement Removal ....................K - 2 Replacement ..................K - 3 K - i K - i...
Page 351 Section K - Engine Contents Page No. K - ii K - ii...
Page 352 Section K - Engine Specification Technical Data Specification Technical Data Type (Robot 160 and 170) 400 Series 4 cylinder in-line, compression ignition, naturally aspirated. Type (Robot 180 and 180T) 400 Series 4 cylinder in-line, compression ignition, turbocharged. Bore (nominal) 84 mm (3.31 in) Stroke 100 mm (3.94 in)
Page 353 Section K - Engine Removal and Replacement Removal The engine and transmission pump should be removed as Disconnect and plug the servo hoses at the pump. an assembly. Label the hoses to ensure correct reassembly. Position the machine on firm level ground. Fully lower Disconnect wiring from the pressure switch on the the arm and stop the engine.
Page 354 Section K - Engine Removal and Replacement Replacement Replacement Replacement is a reversal of the removal procedure. On completion, check hydraulic and cooling system for leakage and level. On completion, check hydraulic and cooling system for leakage and levels. Check function of drive and loader services.
Page 355 Section K - Engine Removal and Replacement Replacement Page left intentionally blank K - 4 K - 4 9803-9450-1...

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