jcb Robot 160 Manuals

Manuals and User Guides for jcb Robot 160. We have 1 jcb Robot 160 manual available for free PDF download: Service Manual

jcb Robot 160 Service Manual (355 pages)

Brand: jcb | Category: Front End Loaders | Size: 42 MB

Section 1 - General Information
3
Table of Contents
4
Introduction
6
About this Publication
6
Identifying Your Machine
7
Machine Model and Serial Number
7
Machine Identification Plate
7
Typical Product Identification Number (PIN)
8
Engine Number
8
Torque Settings
9
Zinc Plated Fasteners and Dacromet Fasteners
9
Introduction
9
Bolts and Screws
9
Hydraulic Connections
13
O' Ring Face Seal System
13
Torque Stop' Hose System
16
Service Tools
17
Numerical List Section B - Body and Framework
17
Tool Detail Reference Section B - Body and Framework
18
Numerical List Section C - Electrics
23
Tool Detail Reference Section C - Electrics
24
Numerical List Section E- Hydraulics
25
Tool Detail Reference Section E- Hydraulics
28
Service Consumables
33
Sealing and Retaining Compounds
33
Section 2 - Care and Safety
35
Safety Notices
38
Safety Check List
38
Safety - Yours and Others
39
General Safety
39
Operating Safety
40
Maintenance Safety
45
Safety Decals
50
Safety Checklist
50
Routine Maintenance
56
Service Requirements
56
Introduction
56
Owner/Operator Support
56
Service/Maintenance Agreements
56
Lifting Regulations - Inspections and Tests
56
Obtaining Replacement Parts
57
Health and Safety
58
Lubricants
58
Battery
60
First Aid - Electrolyte
60
Service Schedules
62
Introduction
62
How to Use the Service Schedules
62
Pre-Start Cold Checks, Service Points and Fluid Levels
63
Functional Test and Final Inspection
65
Fluids, Lubricants and Capacities
67
Coolant Mixtures
67
Cleaning the Machine
69
Cleaning the Cab Interior
70
Checking for Damage
71
Seat Belt
72
Checking the Seat Belt Condition and Security
72
ROPS/FOPS Structure
73
Checking the ROPS/FOPS Structure
73
Boom Safety Strut
74
Installing
74
Removing
75
Greasing
76
Greasing 10 Hours
76
Every 50 Hours
77
Oiling
78
Every 500 Hours
78
Access Panels
79
Engine Cover
79
Rear Panel
79
Electrical System
80
Battery
80
Jump Starting the Engine
81
Fuses and Relays
83
Primary Fuses
83
Engine Air Filter
86
Changing the Elements
86
Cleaning the Air Filter Dust Valve
87
Engine
88
Checking the Oil Level
88
Changing the Oil and Filter
89
Checking the Coolant Level
91
Changing the Coolant
92
Checking the Alternator Belt Tension
94
Adjusting the Alternator Belt
94
Fuel System
95
Types of Fuel
95
Filling the Tank
96
Changing the In-Line Fuel Filter
97
Bleed the Fuel System
97
Draining the Fuel Filter
97
Changing the Fuel Filter Element
98
Bleeding the Fuel System
99
Hydraulic System
100
Checking the Hydraulic Oil Level
100
Changing the Charge Filter Element
101
Changing the Return Filter Element
102
Drive Chain Lubrication
103
Checking the Oil Level
103
Changing the Oil
103
Tyres and Wheels
104
Tyre Inflation
104
Checking the Wheel Nut Torque
104
Renewing Segments of Optional Non-Inflatable Tyres
105
Tracks
106
Track Adjustment
106
Windscreen Washer (Optional)
107
Checking the Level
107
Hydraulic Connections
112
General Information
112
Quick Release Couplings
113
Connecting and Disconnecting
113
Connecting/Disconnecting Hydraulic Hoses
115
Connecting the Hoses
115
Disconnecting the Hoses
115
Maintenance
116
Shovels
116
General Purpose and Light Duty Shovels
116
6-In-1 Shovel
116
Pallet Forks
117
Daily Maintenance
117
Manure/Silage Fork with Top Grab
118
Daily Maintenance
118
Attachment Frame
118
Section B - Body and Framework
121
Loader Arm
124
Removal and Replacement
124
Removal
125
Replacement
126
Rivet Nuts
127
Fitting Procedure
128
Technical Data
134
General Electrical Data
134
Light Bulbs
134
Sensing Switches
135
Test Methods Using a Multimeter
136
Measuring DC Voltage
137
Measuring Resistance
137
Measuring Continuity
138
Measuring Frequency
138
Testing a Diode or a Diode Wire
139
Service Procedures
140
Battery
140
Maintenance
140
First Aid - Electrolyte
140
Testing
141
Specific Gravity Testing
142
Alternator
143
General Description
143
Service Precautions
143
Charging Circuit Test
143
Alternator Charging Test
144
Starting Circuit Test
146
Problem Solving
147
Circuit Diagrams
149
Main Components
149
Lamps
150
Fuses
150
Harness Data
153
Wire and Harness Number Identification
153
Introduction
153
Wire Numbers and Functions
154
General Points
154
Harness Structure
155
Drawings and Interconnection
156
Harnesses
156
Removal and Replacement
179
Removal
179
Replacement
179
Dismantling and Assembling
180
Dismantling
180
Assembling
181
Starter Motor
182
Removal and Replacement
182
Dismantling and Assembly
183
Section D - Controls
188
Manual Controls
190
Technical Data
198
General Data
198
Loader Pump - Standard (P3)
198
Loader Pump - High-Flow (P3 and P5)
198
Charge Pump (P4)
198
Relief Valve Operating Pressures
198
Transmission Pump
199
Hydraulic Motors - Wheeled Machines
199
Hydraulic Motors - Tracked Machines
199
Loader Valve Block - Servo Machines
199
Loader Valve Block - Manual Machines
199
Self Level Valve (Optional)
200
Filters
200
Hydraulic Tank
200
Operation Description
201
Introduction to Hydraulic Schematic Symbols
201
General (Basic and Functional Symbols)
201
Control Valves
205
Example of Schematic Circuit
206
Neutral Circuits
207
Standard Machines
207
High-Flow Machines
208
Loader Circuit
209
Transmission Circuit
209
Servo Circuits
209
Transmission Pump Operation
210
Charge Pressure
210
High Pressure Relief Valves
210
Transmission Motor Operation
212
Loop Flushing System
212
Speed Operation (Optional)
212
Servo Transmission Operation
213
Neutral
213
Forward
214
Reverse
215
Right Spin Turn
216
Loader Valve Operation
217
Neutral Circuit
218
Shovel Tilt
219
Lift Arm Raise
220
Lift Arm Lower
221
Self Level Valve
222
Loader Arm Raise - Self Levelling
222
Tilt Ram Fully Extended
223
Loader Arm Lower
223
Tilt Ram Extend
224
Tilt Ram Retract
224
Power Management System (P.M.S.)
225
Operation
225
Fault Finding
227
Hydrostatic Transmission
227
Hydrostatic Transmission
230
Checking for Faulty Pump or Motor
230
Checking Wheel Speed
232
Machine Veers to One Side When Travelling
234
Transmission Pump Neutral Adjustment
235
Checking Motor Leakage Rate
237
Pump Main Relief Pressure Test Points
238
Testing Main Relief Valves
238
Checking the Joystick Hydraulic Lines
239
Loader Circuit
240
Levelling Circuit
243
High-Flow Circuit
244
Checking Flow and Pressure
244
Warning Light Indications
247
Blink Codes
247
System Check
247
Power Management System (P.M.S.)
247
Fault Tracing
248
General
250
Bleeding the Hydraulic System
250
Circuit Diagrams
251
Standard and High-Flow Servo Machines
251
Component Key
251
Control Variations
253
Component Key
253
Service Procedures
254
Hydraulic Contamination
254
Hydraulic Fluid Quality
254
Effects of Contamination
254
Cleaning Operation
254
Contaminant Standards
255
Filters
255
Cleaning Operation
256
Procedure
256
Pressure Testing
257
Loader Main Relief Valve (M.R.V.)
257
Transmission Charge Pressure
259
Power Management System (P.M.S.)
260
Calibration Procedure
260
To Fit Sensitivity Control to Non High Flow Machines
263
Transmission Pumps
264
Removal and Replacement
264
Removal
264
Replacement
264
Replacement
265
Pump/Engine Coupling
267
Dismantling and Assembly
268
Input Shaft Seal
269
Output Shaft Cover 'O' Ring
269
High Pressure Relief Valves
269
Removal and Replacement
269
Charge Valve
270
Start-Up Procedure
271
Loader Pumps
272
Typical Loader Pump
272
Removal
272
Replacement
272
Loader Pump - Standard Machines
273
Dismantling and Assembly
273
Loader Pump - High-Flow Machines
275
Dismantling and Assembly
275
Drive Motors
277
Motors - Wheeled Machine
277
Removal and Replacement
277
Dismantling
278
Inspection
279
Assembly
279
Motor Bearing Housing
281
Assembly
284
Motors - Tracked Machine
287
Removal and Replacement
287
Brake Dismantling and Assembly
289
Front Housing
291
Section F - Transmission
294
Drive Train
296
Section F - Transmission Description
297
Tracked Machines
298
Tyres and Wheels
299
Roadwheels
299
Removal
299
Replacement
299
Wheel Hubs and Drive Shafts
300
Wheel Hub Assembly (Right Hand)
300
Removal
300
Replacement
300
Dismantling
302
Assembly
303
Drive Shaft Assembly (Left Hand)
305
Dismantling
306
Assembly
306
Drive Chains
308
Removal and Replacement
308
Removal
308
Replacement
309
Adjustment
310
Section G - Brakes
314
Moving a Disabled Machine
316
Basic System and Operation
322
Description
322
Track Damage
324
Types of Rubber Track Damage
324
Additional Notes
325
Track Repair
334
Recommended Repair Procedures
334
Track Removal and Replacement
336
Removal
336
Replacement
338
Idler Wheels and Rollers
339
Front Idler Wheel and Recoil Unit
339
Rear Idler Wheel
341
Guide Roller
343
Track Frame Assembly
345
Removal
345
Replacement
346
Technical Data
352
Section K - Engine Specification
352
Removal and Replacement
353

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