JCB Robot 160, 170 & 180 Skid Steer Loader Repair Service Manual

(S/N: 1602000 to 1604999) - (S/N: 1803000 to 1806999)
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This service manual PDF download for the Robot 160, 170 and 180 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 160 - S/N: 1602000 to 1604999
JCB Robot 170, 170HF, 180, 180HF - S/N: 1602000 to 1604999
JCB Robot 180T, 180T HF - S/N: 1803000 to 1806999

This manual provides information for the following wheeled models in the JCB Skid Steer Loader Range.
– JCB Robot 160 serial number 1602000 to 1604999.
– JCB Robot 160HF serial number 1602000 to 1604999.
– JCB Robot 170 serial number 1602000 to 1604999.
– JCB Robot 170HF serial number 1602000 to 1604999.
– JCB Robot 180 serial number 1602000 to 1604999.
– JCB Robot 180HF serial number 1602000 to 1604999.

This manual also provides information for the following tracked models in the JCB Skid Steer Loader Range.
– JCB Robot 180T serial number 1803000 to 1806999.
– JCB Robot 180T HF serial number 1803000 to 1806999.

Information also covers both wheeled and tracked machines unless otherwise stated.


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 D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section J - Tracks
Section K - Engine


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9450-1
Total Pages : 386


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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9803-9450-1
JCB Robot 160, 170 and 180

Section 1 - General Information
General Information
Identifying your Machine
Torque Settings
Service Tools
Service Consumables
Introduction
About this Publication
Identifying your Machine
Machine Model and Serial Number
Machine Identification Plate
Typical Product Identification Number (PIN)
Engine Number
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
'Torque Stop' Hose System
Service Tools
Numerical List Section B - Body and Framework
Tool Detail Reference Section B - Body and Framework
Numerical List Section C - Electrics
Tool Detail Reference Section C - Electrics
Numerical List Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
Service Consumables
Sealing and Retaining Compounds

Section 2 - Care and Safety
Care and Safety
Safety Check List
Safety Notices
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals

Section 3 - Maintenance
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 3 - 2
Health and Safety 3 - 3
Lubricants 3 - 3
Battery 3 - 5
First Aid - Electrolyte 3 - 5
Service Schedules 3 - 7
Introduction 3 - 7
How to Use the Service Schedules 3 - 7
Pre-start Cold Checks, Service Points and Fluid Levels 3 - 8
Functional Test and Final Inspection 3 - 10
Fluids, Lubricants and Capacities 3 - 12
Coolant Mixtures 3 - 12
Cleaning the Machine 3 - 14
Cleaning the Cab Interior 3 - 15
Checking for Damage 3 - 16
Seat Belt 3 - 17
Checking the Seat Belt Condition and Security 3 - 17
ROPS/FOPS Structure 3 - 18
Checking the ROPS/FOPS Structure 3 - 18
Boom Safety Strut 3 - 19
Installing 3 - 19
Removing 3 - 20
Greasing 3 - 21
Greasing 10 Hours 3 - 21
Every 50 Hours 3 - 22
Oiling 3 - 23
Every 500 Hours 3 - 23
Access Panels 3 - 24
Engine Cover 3 - 24
Rear Panel 3 - 24
Electrical System 3 - 25
Battery 3 - 25
Jump Starting the Engine 3 - 26
Fuses and Relays 3 - 28
Engine Air Filter 3 - 31
Changing the Elements 3 - 31
Cleaning the Air Filter Dust Valve 3 - 32
Engine 3 - 33
Checking the Oil Level 3 - 33
Changing the Oil and Filter 3 - 34
Checking the Coolant Level 3 - 36
Changing the Coolant 3 - 37
Checking the Alternator Belt Tension 3 - 39
Adjusting the Alternator Belt 3 - 39
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 3 - 43
Bleeding the Fuel System 3 - 44
Hydraulic System 3 - 45
Checking the Hydraulic Oil Level 3 - 45
Changing the Charge Filter Element 3 - 46
Changing the Return Filter Element 3 - 47
Drive Chain Lubrication 3 - 48
Checking the Oil Level 3 - 48
Changing the Oil 3 - 48
Tyres and Wheels 3 - 49
Tyre Inflation 3 - 49
Checking the Wheel Nut Torque 3 - 49
Renewing Segments of Optional Non-Inflatable Tyres 3 - 50
Tracks 3 - 51
Track Adjustment 3 - 51
Windscreen Washer (optional) 3 - 52
Checking the Level 3 - 52
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Lifting Regulations - Inspections and Tests
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid - Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid - Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
Introduction
How to Use the Service Schedules
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Cleaning the Machine
Cleaning the Cab Interior
Checking for Damage
Seat Belt
Checking the Seat Belt Condition and Security
ROPS/FOPS Structure
Checking the ROPS/FOPS Structure
Boom Safety Strut
Installing
Removing
Greasing
Greasing 10 Hours
Quickhitch Pivot Pins
Every 50 Hours
Loader Arm Pivot Point
Lift Ram Pivots
Oiling
Every 500 Hours
Safety Restraint mechanism
Throttle Pedal (if fitted)
Access Panels
Engine Cover
Opening and Closing
Opening
Closing
Rear Panel
Removing the Panel
Refitting the Panel
Electrical System
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Jump Starting the Engine
Fuses and Relays
Primary Fuses
Individual Circuit Fuses
Relays
Engine Air Filter
Changing the Elements
Cleaning the Air Filter Dust Valve
Engine
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Changing the Coolant
Checking the Alternator Belt Tension
Adjusting the Alternator Belt
Fuel System
Types of Fuel
Recommended Fuel Specification
Acceptable Fuel Specification
Sulphur Content
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Petrol
Filling the Tank
Changing the In-line Fuel Filter
Draining the Fuel Filter
Changing the Fuel Filter Element
Bleeding the Fuel System
Hydraulic System
Checking the Hydraulic Oil Level
Changing the Charge Filter Element
Changing the Return Filter Element
Drive Chain Lubrication
Checking the Oil Level
Changing the Oil
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torque
Renewing Segments of Optional Non- Inflatable Tyres
Tracks
Track Adjustment
Windscreen Washer (optional)
Checking the Level

Section A - Attachments
Attachments
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 A - 4
Maintenance
Shovels A - 5
General Purpose and Light Duty Shovels A - 5
6-in-1 Shovel A - 5
Pallet Forks A - 6
Daily Maintenance A - 6
Manure/Silage Fork with Top Grab A - 7
Daily Maintenance A - 7
Attachment Frame A - 7
Hydraulic Connections
General Information
Quick Release Couplings
Connecting and Disconnecting
Quick Release Couplings - Do's and Don'ts
Connecting Quick Release Couplings
Disconnecting Quick Release Couplings
Connecting/Disconnecting Hydraulic Hoses
Connecting the Hoses
Disconnecting the Hoses
Maintenance
Shovels
General Purpose and Light Duty Shovels
Daily Maintenance
6-in-1 Shovel
Daily Maintenance
Pallet Forks
Daily Maintenance
Manure/Silage Fork with Top Grab
Daily Maintenance
Attachment Frame
Daily Maintenance

Section B - Body and Framework
Body and Framework
Loader Arm
Removal and Replacement
Removal
Replacement
Fasteners
Rivet Nuts
Fitting Procedure

Section C - Electrics
Electrics
Technical Data
General Electrical Data
Light Bulbs
Sensing Switches
Test Methods
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Service Procedures
Battery
Maintenance
First Aid - Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starting Circuit Test
Problem Solving
Circuit Diagrams
Main Components
Lamps
Fuses
Harness Data
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Structure
Drawings and Interconnection
Harnesses
Alternator
Removal and Replacement
Removal
Replacement
Dismantling and Assembling
Dismantling
Assembling
Starter Motor
Removal and Replacement
Dismantling and Assembly
Dismantling
Servicing
Assembling

Section D - Controls
Controls
Manual Controls
Dismantling and Assembly
Manual Control Linkage - Foot Operated Loader

Section E - Hydraulics
Hydraulics
Technical Data
General Data
Loader Pump - Standard (P3)
Loader Pump - High-Flow (P3 and P5)
Charge Pump (P4)
Relief Valve Operating Pressures
Transmission Pump
Hydraulic Motors - Wheeled Machines
Hydraulic Motors - Tracked Machines
Loader Valve Block - Servo Machines
Loader Valve Block - Manual Machines
Self Level Valve (optional)
Filters
Rams
Dimensions
Torque Settings
Hydraulic Tank
Operation Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Neutral Circuits
Standard Machines
High-flow Machines
Loader Circuit
Transmission Circuit
Servo Circuits
Transmission Pump Operation
Charge Pressure
High Pressure Relief Valves
Transmission Motor Operation
Loop Flushing System
2 Speed Operation (optional)
Servo Transmission Operation
Neutral
Forward
Reverse
Right Spin Turn
Loader Valve Operation
Neutral Circuit
Shovel Tilt
Lift Arm Raise
Lift Arm Lower
Self Level Valve
Loader Arm Raise - Self Levelling
Tilt Ram Fully Extended
Loader Arm Lower
Tilt Ram Extend
Tilt Ram Retract
Power Management System (P.M.S.)
Operation
Warning Light Indications
Fault Finding
Hydrostatic Transmission
Checking for Faulty Pump or Motor
Checking Wheel Speed
Maximum Displacement Adjustment
Machine Veers to One Side when Travelling
Adjustment
Transmission Pump Neutral Adjustment
Checking Motor Leakage Rate
Pump Main Relief Pressure Test Points
Testing Main Relief Valves
Checking the Joystick Hydraulic Lines
Loader Circuit
Levelling Circuit
High-flow Circuit
Checking Flow and Pressure
Power Management System (P.M.S.)
Warning Light Indications
Blink Codes
System Check
Fault Tracing
General
Bleeding the Hydraulic System
Circuit Diagrams
Standard and High-flow Servo Machines
Component Key
Control Variations
Component Key
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Cleaning Operation
Procedure
Pressure Testing
Loader Main Relief Valve (M.R.V.)
Transmission Charge Pressure
Power Management System (P.M.S.)
Calibration Procedure
To fit Sensitivity Control to Non High Flow Machines
Transmission Pumps
Removal and Replacement
Removal
Replacement
Pump/Engine Coupling
Dismantling and Assembly
Input Shaft Seal
Removal and Replacement
Output Shaft Cover ‘O’ Ring
Removal and Replacement
High Pressure Relief Valves
Dismantling and Assembly
Charge Valve
Dismantling and Assembly
Start-Up Procedure
Loader Pumps
Typical Loader Pump
Removal
Replacement
Loader Pump - Standard Machines
Dismantling and Assembly
Dismantling
Inspection
Gears and Shafts
Housing and Covers
Assembly
Loader Pump - High-flow Machines
Dismantling and Assembly
Dismantling
Inspection
Gears and Shafts
Housing and Covers
Assembly
Drive Motors
Motors - Wheeled Machine
Removal and Replacement
Removal
Replacement
Dismantling
Inspection
Assembly
Motor Bearing Housing
Removal and Replacement
Removal
Replacement
Dismantling
Assembly
Motors - Tracked Machine
Removal and Replacement
Removal
Replacement
Brake Dismantling and Assembly
Dismantling
Assembly
Motor Dismantling
Rotating and Rear Casing Assembly
Flushing Spool Assembly
Front Housing
Reassembling
Front Housing
Rotating and Rear Casing Assembly
Flushing Spool Assembly
Completion
Valves
Loader Valve - Servo Machines
Removal
Replacement
Hose Connections
Dismantling
Assembly
Loader Valve - Manual Machines
Removal
Replacement
Hose Connections
Dismantling
Assembly
Self Level Valve
Removal
Replacement
Dismantling
Inspection
Assembly
Servo Cut-off Valve
Removal
Replacement
Hose Connections
Brake and Power Management System (P.M.S.) Dump Valve
Removal
Replacement
Hose Connections
Float Valve
Removal
Replacement
Rams
Loader Arm Lift Ram
Removal
Replacement
Quickhitch Tilt Ram
Removal
Replacement
Typical Ram
Dismantling and Assembly
When Dismantling
When Assembling
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
Servo Joysticks
Removal and Replacement
Removal
Replacement
Hose Connections
Dismantling and Assembly
Dismantling
Assembly
Torque Settings

Section F - Transmission
Transmission
Description
Drive Train
Tracked machines
Tyres and Wheels
Roadwheels
Removal
Replacement
Wheel Hubs and Drive Shafts
Wheel Hub Assembly (right hand)
Removal
Replacement
Dismantling
Inspection
Assembly
Drive Shaft Assembly (left hand)
Dismantling
Inspection
Assembly
Drive Chains
Removal and Replacement
Removal
Replacement
Adjustment
Left Hand Chain Adjustment
Right Hand Chain Adjustment

Section G - Brakes
Brakes
Moving a Disabled Machine
Towing/Winching
Preparation for Towing/Winching
After Towing/Winching

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

Section K - Engine
Engine
Specification
Technical Data
Removal and Replacement
Removal
Replacement

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