JCB Robot 260W, 280W, 300W, 330W, 260T, 300T, 320T Skid Steer Loader Repair Service Manual

(S/N: 1745010 Onwards)
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This service manual PDF download for the Robot 260W, 280W, 300W, 330W, 260T, 300T, 320T JCB Skid Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

JCB Skid Steer Loader

JCB Robot 260W
JCB Robot 280W
JCB Robot 300W
JCB Robot 330W
JCB Robot 260T
JCB Robot 300T
JCB Robot 320T

S/N: 1745010 Onwards


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Tracks
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9950-1
Total Pages : 470


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9950

Section 1 - General Information
Introduction
About this Publication
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cab/Canopy
Machine Description
The JCB Skid Steer Loader
Intended Use
Component Locations
Identifying Your Machine
Machine Identification Plate
Component Identification
ROPS and FOPS
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
'O' Ring Face Seal System
Service Tools
Numerical List
Tool Detail Reference
Section B - Frame and Bodywork
Section C - Electrics
Section E - Hydraulics
Section K - Engine
Service Aids
Sealing and Retaining Compounds

Section 2 - Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety

Section 3 - Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Service Label
Pre-start Cold Checks, Service Points and Fluid Levels
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels
Tools
Carrying Tools onto the Machine
Tool Locations (optional)
Prepare the Machine for Maintenance
Introduction
How to Prepare the Machine for Maintenance (Loader Arm Lowered)
How to Prepare the Machine for Maintenance (Loader Arm Lifted)
How to Prepare the Machine for Maintenance (Loader Arm and Cab Lifted)
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Checking the ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Every 50 Hours
Access Panels
Introduction
Rear Door
Engine Top Cover
Cab
Heater and Air Conditioning (option)
Changing the Intake Filter
Changing the Re-circulation Filter
Electrical System
Battery
Jump Starting the Engine
Fuses and Relays
Battery Isolator (Option)
Engine
Oil and Filters
Cooling system
Alternator Belt
Engine Air Filter
Fuel System
Introduction
Draining the Primary Water Separator and Engine Fuel Filter
Changing the Primary Water Separator Filter
Fuel Filter
Hydraulic System
Introduction
Releasing the Auxiliary Hydraulic Pressure
Oil and Filters
Hydraulic Tank Breather
Transmission
Drive Chain Lubrication - Wheeled Machines
Drain Line Screen Filter Adapter
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Tracks
Track Adjustment
Front Screen Washer (optional)
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A - Attachments
Optional Attachments
Introduction
Attachments For Your Machine
Impact Protection
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Auxiliary Operation
Normal Operation
High Flow Operation
Hydraulic Quick Hitch Control
To Release the Attachment
To Engage the Attachment
Manual Quickhitch Control
Engaging the Shovel/Attachments
Disengaging the Shovel/Attachments
Attachment Frame
Installation and Removal
Shovels
6-in-1 Shovel
Grapple Bucket
Installation and Removal
Operation
Maintenance
Storage
Pallet Forks
Installation and Removal
Operation
Road Travel
Maintenance
Manure/Silage Fork with Top Grab
Installation and Removal
Operation
Preparing for Travel
Maintenance
Snow Blade
Installation and Removal
Operation
Maintenance

Section B - Body and Framework
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Glazing
Direct Glazing
Cab/Canopy
Removal and Replacement
Removal
Replacement
Loader Arm
Removal and Replacement
Removal
Replacement
Stop Pad Adjustment
Cab/Canopy Door
Removal and Replacement
Removal
Replacement
Locks and Handles
Removal
Replacement

Section C - Electrics
Technical Data
General Electrical Data
Light Bulbs
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Radio
Technical Data
General
FM Tuner
AM Tuner
Weather Band
Amplifier
Wiring Diagram
Electronic Throttle Control
Description and Operation
Description
Operation
Fault Codes
Installtion
Circuit Diagrams
Components
Diagrams
Harness Data
Drawings and Interconnection
Cab Harrness
Cab Harness - Multifunction
Chassis Harness
Chassis Harness - Multifunction
Windscreen Washer Harness
Engine Harness
Front Wash Wipe Harness
Rear Wash Wipe Harness
Logic Control
Introduction
Description
Error Codes
Machine Error Codes
Alternator
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Starter Motor
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Brush Gear
Renewing the Starter Solenoid
White Noise/Reverse Alarm
Removal, Inspection and Replacement
Work Lights
Removal, Inspection and Replacement
Work Light Mounting Brackets
Work Light Assemblies
Road Lights
Removal, Inspection and Replacement
Road Light Assemblies

Section E - Hydraulics
Technical Data
General Data
Main Valve Block
Smooth Ride System Valve Block
Servo Cut Off Manifold
Servo Cut Off Manifold 2 Speed
Self Level Valve (Optional)
Loader Pump - Standard (P3)
Loader Pump - High-Flow (P3 and P5)
Charge Pump (P4)
Return Line Filter
Return Line Filter (High Flow)
Rams
Hydraulic Tank
Circuit Diagrams
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Standard and High-flow Servo Machines
Component Key
Valves
Main Valve Block
Description
Removal
Replacement
Smooth Ride System Valve
Description
Removal
Replacement
Combination Valve
Description
Removal
Replacement
Self Level Valve (Optional)
Description
Removal
Replacement
Servo Joysticks
Description and Operation
Description
Operation
Removal and Replacement
Removal
Replacement
Gear Pumps
Description
General
Removal and Replacement
Introduction
Removal
Replacement
Dismantling and Assembly
Shaft Seal Replacement
Motor
Hydraulic Fan Motor
Introduction
Removal
Replacement
Hydraulic System
Hydraulic Tank
Introduction
Removal
Replacement
Return Line Filter
Introduction
Removal
Replacement
Return Line Filter (High Flow)
Introduction
Removal
Replacement
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Introduction
Loader Arm Lift Ram
Removal
Replacement
Quickhitch Tilt Ram
Removal
Replacement
Typical Ram
Dismantling and Assembly
Dismantling
Assembly
New Rod and Piston Head
New Piston Head Fitted to a Pre-drilled Piston Rod
New Piston Rod Fitted to a Pre-drilled Piston Head
JCB Ram Sealing Procedure
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Quick Release Couplings
Connecting and Disconnecting
Smooth Ride System (SRS) Accumulator
Charging and Discharging
`Positional Type' Hydraulic Adaptors
Fitting Procedure
Hydraulics
Pressure Testing
Bleeding the System
Push Lock Fittings (XDT)
Fitting Procedure
Rapid Assembly Hose Fittings
Fitting Procedure
ORFS Hose Connections
Fitting Procedure
Fault Finding
Hydrostatic Transmission
Machine veers to one side when travelling
Loader Circuit
Levelling Circuit

Section F - Transmission
Technical Data
General Data
Transmission Pump (P1 and P2)
Transmission Circuit
Description
General
Circuit Descriptions
No Drive
Forwards Drive
Reverse Drive
Right Spin Turn
High Speed
Transmission Pumps
Description
General
DA Control Valve
Pump/Engine Coupling
Removal and Replacement
Removal
Replacement
Adjustment
Low Pressure Valve (Charge Pressure)
High Pressure (HP) Valves
Mechanical Zero Position
DA Control
Dismantling and Assembly
Drive Shaft Seal
Control Piston Cover Seal
Valve Seals
Start-Up Procedure
Drive Motors
Description and Operation
Description
2 Speed Operation (optional)
Flushing Valve Operation
Parking Brake Operation
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Park Brake
Motor - Wheeled Machines
Motor - Tracked Machines
Front Casing - Wheeled Machines
Front Casing - Tracked Machines
Rotating Assembly
Rear Casing
Flushing Valve
Two Speed Spool
Transmission Motor Operation
Loop Flushing System
Two Speed Operation (optional)
Drain Line Screen Filter Adapter
Replacment
Drive Chains
Removal and Replacement
Removal
Replacement
Axle Hubs
Wheel Hub Assembly
Removal
Replacement
Dismantling
Inspection
Assembly
Tyres and Wheels
Roadwheels
Removal
Replacement

Section J - Tracks
Basic System and Operation
Description
Running Gear Components
Track Construction
Track Serial Number Location and Production Date
Tracks
Removal and Replacement
Removal
Replacement
Sprocket
Removal and Replacement
Removal
Replacement
Track Frame Assembly
Removal and Replacement
Removal
Replacement
Idler Wheels and Recoil Unit
Front Idler Wheel and Recoil Unit
Removal
Replacement
Dismantling and Assembly
Rear Idler Wheel
Removal
Replacement
Dismantling and Assembly
Guide Roller
Removal
Replacement
Dismantling and Assembly
Track Damage
Types of Rubber Track Damage
Core Bars - Separation
Core Bars - Breaking
Core Bars - Fast Abrasion
Core Bars - Oxidation (Rusting)
Steel Cord - Breaking
Steel Cord - Separation
Steel Cord - Exposure
Steel Cord - Sticking Out
Outer Track Rubber - Tearing/Cuts
Outer Track Rubber - Fast Abrasion
Outer Track Rubber - Cracks
Outer Track Rubber - Longitudinal Cracks
Inner Track Rubber - Tearing/Cuts
Inner Track Rubber - Cracks
Miscellaneous - Not Engaging Correctly
Miscellaneous - Detracking
Track Repair
Recommended Repair Procedures
Additional Notes:

Section K - Engine
Technical Data
JCB 444 Series
Specifications

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