R
Service Manual ROBOT 150, 165 PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, STAFFORDSHIRE, ST14 5PA, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/8500
General Information
1
Care & Safety
2
Routine Maintenance
3
Attachments
A
Body & Framework
B
Electrics
C
Controls
D
Hydraulics
E
Transmission
F
Brakes
G
Engine
K
Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3 machine.
= = =
General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B
= =
Attachments Body & Framework
...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
9803/8500
Issue 1
General Information
Section 1
Section 1
i
i
Contents
9803/8500
Page No.
Identifying your Machine
1-1
Torque Settings
2-1
Service Tools - Numerical List - Electrics - Hydraulics
3-1 4-1 4-2
Sealing and Retaining Compounds
5-1
Issue 1
Section 1
General Information
Section 1
1-1
Identifying your Machine
1-1
The serial number of the chassis, engine, lift arm and hydraulic pump unit positively identify the type of JCB Skid Steer Loader you have.
Machine Identification Plate The machine identification plate A is located as shown. It is stamped with the serial numbers of the major individual units.
A S173720
Typical Vehicle Identification Number (VIN) SLP
165
S
B
V
E
677001
1
2
3
4
5
6
7
1 World Manufacturer Identification 2 Machine Model
J.C.BAMFORD EXCAVATORS LTD. ROCESTER, STAFFS, ENGLAND.
R
CONSTRUCTOR
Vehicle Identification No.
3 Machine Type (S = Standard, H = High-flow)
MADE IN UK
Product Identification No.
ENGINE SERIAL No.
WEIGHT
PUMP SERIAL No. MODEL 80/1269/EEC POWER KW R.P.M. 150 35 2800 2800 35 165 35 2800 165 HF
YEAR OF MANUFACTURE MODEL 80/1269/EEC POWER KW R.P.M. 2800 1CX 35 2800 35 1CX HF 185 52 2200 52 2200 185 HF
4 Build Type (A = Canopy, B = Cab) 5 Year of Manufacture: T = 1996 V = 1997 W = 1998 X = 1999 Y = 2000
1 = 2001 2 = 2002 3 = 2003 4 = 2004 5 = 2005
817/04437
6 Manufacturer Location (E = England) 7 Product Identification Number (PIN)
9803/8500
Issue 5
Section 1
General Information
Section 1
1-2
Identifying your Machine
1-2
Unit Identification * The engine serial number on XUD engines is stamped on a machined area B on the top of the cylinder block. On JCB Diesel engines the number is stamped on a label G on the left side of the cylinder block. The chassis serial number is stamped on the front edge of the right hand mudguard as shown at C. On early machines the serial number is stamped on the right hand side of the machine as shown at F.
B S173730
The lift arm serial number is stamped on the rear of the lift arm as shown at D.
G
The hydraulic pump unit serial number is stamped on a plate on the top of the pump at E. If any of the above units are replaced with new ones, the relevant serial number on the Machine Identification Plate will be superseded. Either stamp the plate with the new number or stamp out the old number.
S255430
C F S173742
D E S173750
S173760
Y Left Side, Right Side In this manual, 'left' X and 'right' Y mean your left and right when you are seated correctly in the machine.
X 9803/8500
S173660
Issue 2*
General Information
Section 1 2-1
Section 1 2-1
Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size in 1/4 * 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 11/4 11/2
(mm)
Hexagon (A/F) in
(6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)
7/16
11/8 15/16 11/2 17/8 21/4
Bolt Size in
(mm)
Hexagon (A/F) in
M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)
8 10 13 17 19 24 30 36 46 55
1/2 9/16 5/8 3/4 13/16 15/16
Nm 14 28 49 78 117 170 238 407 650 970 1940 3390
Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0
lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500
Metric Grade 8.8 Bolts
Nm 7 12 28 56 98 244 476 822 1633 2854
Torque Settings kgf m
lbf ft
0.7 1.2 3.0 5.7 10 25 48 84 166 291
5 9 21 42 72 180 352 607 1205 2105
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/8500
Issue 2*
Section 1 3-1
General Information
Section 1 3-1
Service Tools
Numerical List
* * * * * * * *
1406/0011 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1612/0006 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/1201 4104/0251 4104/0253 4104/1557 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/50043 816/55038 816/55040 816/60096 892/00047 892/00048 892/00055 892/00056 892/00057 892/00059 892/00060 892/00074 892/00075 892/00077 892/00137 892/00223 892/00252 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265
9803/8500
Page No. Bonded Washer 4-3 Bonded Washer 4-3 Bonded Washer 4 - 2/4 - 3 Bonded Washer 4-3 Adapter 4-3 Adapter 4-3 Adapter 4 - 2/4 - 3 Adapter 4-3 Adapter 4-3 Adapter 4-3 Adapter 4-3 Adapter 4-3 Adapter 4-2 Threadlocker and Sealer 5-1 Threadlocker 5-1 Threadlocker and Sealer (High Strength) 5 - 1 Retainer (High Strength) 5-1 High Strength Threadlocker 5-1 Multi-Gasket 5-1 Activator (Aerosol) 5-1 Activator (Bottle) 5-1 JCB Cleaner/Degreaser 5-1 Blanking Cap 4-4 Blanking Cap 4-4 Blanking Cap 4-4 Blanking Cap 4-4 Blanking Cap 4-4 Blanking Cap 4-4 Pressure Test Adapter 4-2 Adapter 4-2 'T' Adapter 4-4 Pressure Test 'T' Adapter 4-2 Pressure Test 'T' Adapter 4-2 'T' Adapter 4-4 'T' Adapter 4-4 'T' Adapter 4-4 Blanking Plug 4-4 Blanking Plug 4-4 Blanking Plug 4-4 Blanking Plug 4-4 Blanking Plug 4-4 Female Connector 4-4 Female Connector 4-4 Female Connector 4-4 Hose 4-3 Hand Pump 4-3 A.R.V Test Block - Husco 4-3 Pressure Test Kit 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test Adapter 4-2 Pressure Test 'T' Adapter 4 - 2/4 - 3 Pressure Test 'T' Adapter 4-2 Pressure Test 'T' Adapter 4-2 Pressure Test 'T' Adapter 4-2
892/00268 892/00269 892/00270 892/00271 892/00272 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00706 892/00858 892/00923 992/09300 992/09400 992/09500 992/09600 993/68100 993/85700 993/99510
Page No. Flow Monitoring Unit 4-2 Sensor Head 4-2 Load Valve 4-2 Adapter 4-2 Adapter 4-2 Adapter 4-3 Adapter 4-2 Adapter 4-2 Adapter 4-2 Gauge 4-3 Gauge 4-3 AVO Meter 4-1 Shunt 4-1 Tool Kit Case 4-1 Tachometer 4-1 Hydraulic Oil Temperature Probe 4-1 Surface Temperature Probe 4-1 Test Probe 4-3 Pump Support Bracket 4-3 A.R.V Test Block - Commercial Hyd. 4-3 Spanner 4-3 Spanner 4-3 Spanner 4-3 Spanner 4-3 Slide Hammer 4-4 Battery Tester 4-1 Half Moon Spanner 4-4
The following parts are replacement items for kits and would normally be included in the kit numbers quoted above. Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 892/00202 Replacement Gauge 892/00203 Replacement Gauge 892/00254 Replacement Hose
4-2 4-2 4-2 4-2
Issue 8*
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Section 1
General Information
4-1
Section 1 4-1
Service Tools
Section C - Electrics
AVO Test Kit 1
892/00283
Tool Kit Case
2
892/00281
AVO Meter
3
892/00286
Surface Temperature Probe
4
892/00284
Microtach Digital Tachometer
5
892/00282
Shunt - open type
6
892/00285
Hydraulic Oil Temperature Probe
188230
* 993/85700
Battery Tester
239510
9803/8500
Issue 2*
General Information
Section 1 4-2
Section 1 4-2
Service Tools
Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit 892/00253
Pressure Test Kit
892/00201
Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202
Replacement Gauge 0-40 bar (0-600 lbf/in2)
* 892/00203 892/00254
Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose
188120
200140 188130
Pressure Test Adapters Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265
892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261
1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSPP x Test Point
1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point
Flow Test Equipment
188150
9803/8500
892/00268 892/00269 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277
Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP
Issue 2*
General Information
Section 1 4-3
Section 1 4-3
Service Tools
Section E - Hydraulics
220840
A215880
892/00858 Pump support bracket - for engine removal.
S270650
* 892/00252 Test Block for A. R. V. - Husco valves * 892/00923 Test Block for A. R. V. - Commercial Hydraulic valves
193850
188140
Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279
Bonded Washers
Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)
1406/0011 1406/0018 1406/0021 1406/0029
1/4 in BSP 1/2 in BSP 3/4 in BSP 1.1/4 in BSP
193860 193930
Male Adapters - BSP x BSP 1606/0003 1604/0003 1606/0004 1606/0007 1604/0004 1606/0008 1606/0009 1604/0006
9803/8500
3/8 in x 1/4 in 3/8 in x 3/8 in 1/2 in x 1/4 in 1/2 in x 3/8 in 1/2 in x 1/2 in 3/4 in x 3/8 in 3/4 in x 1/2 in 3/4 in x 3/4 in
Hexagon Spanners for Ram Pistons and End Caps 992/09300 992/09400 992/09500 992/09600
55 mm A/F 65 mm A/F 75 mm A/F 85 mm A/F
Issue 5*
General Information
Section 1 4-4
Section 1 4-4
Service Tools
Section E - Hydraulics
193880 193870
Male Cone Blanking Plug Female Cone Blanking Plug 892/00055 892/00056 892/00057 892/00059 892/00060
816/00294 816/00189 816/00190 816/00197 816/00196 816/00193
1/4 in BSP 3/8 in BSP 1/2 in BSP 3/4 in BSP 1 in BSP'T'
1/4 in BSP 3/8 in BSP 1/2 in BSP 5/8 in BSP 3/4 in BSP 1 in BSP
193890
'T' Adapters 892/00047 892/00048 816/50043 816/60096
193900
Female Connectors 3/8 in BSP (A) x 1/4 in BSP (B) 1/2 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B)
892/00074 892/00075 892/00077
* 993/68100 193910
993/99510
3/8 in BSP x 3/8 in BSP 1/2 in BSP x 1/2 in BSP 3/4 in BSP x 3/4 in BSP
Slide Hammer Half Moon Spanner
193920
9803/8500
Issue 2*
General Information
Section 1 5-1
JCB Multi-Gasket
Section 1 5-1
Sealing and Retaining Compounds A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
JCB High Strength Threadlocker A high strength locking fluid for use with threaded components.
4102/1201
4102/0551
JCB Retainer (High Strength)
For retaining parts which are unlikely to be dismantled.
4101/0651
JCB Threadlocker & Sealer
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm dia., and for hydraulic fittings up to 25 mm dia.
4101/0251
JCB Threadlocker & Sealer (High Strength)
A medium to high strength locking fluid for retention and sealing of ram piston heads.
4101/0552
JCB Threadlocker
A locking fluid for use on threads larger than 50 mm dia.
4101/0451
JCB Activator
A cleaning primer which speeds the curing rate of anaerobic products.
JCB Cleaner/Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/0251 4104/0253
Aerosol Bottle
4104/1557
Aerosol
The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E). The list above has been changed accordingly. References to these products on subsequent pages in this service manual will be progressively updated but for convenience a cross reference table is shown below.
Old Description
Old Part Number
JCB High Strength Threadlocker 4102/0502
New Description
New Part Number
JCB High Strength Threadlocker
4102/0551
JCB High Strength Retainer
4101/0602
JCB Retainer (High Strength)
4101/0651
JCB Lock & Seal
4101/0202
JCB Threadlocker & Sealer
4101/0251
Loctite 243
4101/1101
Use 4101/0251
Loctite 262
4101/0502
JCB Threadlocker & Sealer (High Strength)
4101/0552
Loctite 932
4101/0402
JCB Threadlocker
4101/0451
Loctite Activator N
4104/0101 Aerosol 4104/0102 Bottle
JCB Activator
4104/0251 4104/0253
JCB Cleaner & Degreaser
4104/1538 Aerosol
JCB Cleaner/Degreaser
4104/1557
9803/8500
Issue 5