jcb ROBOT 150 Service Manual Download Page 119

Page: 119 / 254

7 - 3

Panel/Cab Harness (cont'd)

Wire No

Wire Function

Size
(mm)

410

Pre-heat Timer Relay to Warning Light via Plug 1 Pin 11

1.0

411

Water Temperature Warning Light to Switch via Plug 1 Pin 12

1.0

412

Engine Oil Pressure Warning Light to Water Temperature Warning Light

1.0

413

Water Temperature Warning Light to Air Filter Warning Light

1.0

414

Air Filter Warning Light to Low Fuel Warning Light

1.0

415

Water Temperature Warning Light to Diode

1.0

416

Air Filter Warning Light to Switch via Plug 1 Pin 13

1.0

417

Low Fuel Warning Light to Switch via Plug 1 Pin 14

1.0

418

Low Fuel Warning Light to Hydraulic Oil Pressure Warning Light

1.0

419

Hydraulic Oil Pressure Warning Light to Diode

1.0

420

Hydraulic Oil Pressure Warning Light to Switch via Plug 2 Pin 1

1.0

421

Reverse Alarm to Switch 2 via Plug 2 Pin 2

1.0

424

Hydraulic Oil Temperature Warning Light to Charge Pump Warning Light

1.0

425

Flasher Relay to Warning Light Indicator Switch

1.0

426

Warning Unit Signal to Warning Light

1.0

602

Front Work Light Switch to Earth Splice SA

1.0

605

Hourmeter to Earth Splice SM

1.0

606

Front Roof Earth Splice to Earth Splice SA

2.0

608

Pre-heat Warning Light to Earth Splice SM

1.0

611

Interior Light to Earth Splice SM

1.0

616

Flasher Relay to Earth Splice SK

1.0

623

Panel Earth Splice to Earth via Plug 2 Pin 3

2.0

624

Rear Roof Harness Earth Splice to Earth Splice via Plug 2 Pin 4

2.0

626

Earth Splice to Earth (Sk) via Plug 2 Pin 5

2.0

627

Front Working Light Switch Earth to Rear Working Light Switch Earth

1.0

632

Brake Switch to Earth Splice SM

1.0

635

Auxiliary Hydraulic Switch Earth to Earth Splice SA

1.0

638

Earth Splice to Earth (SM) via Plug 2 Pin 6

2.0

639

Earth From Splice SA to Low Water Warning Unit

1.0

642

Earth From Splice SK to Auxiliary Neutral Start Relay

1.0

643

From Splice SM to Heated Seat Illumination

1.0

644

From SK to FC (Heated Seat Plug)

1.0

801

Front Work Light Switch to Work Light Splice

1.0

803

Rear Work Light Switch to Rear Work Light

1.0

804

Rear Work Light Switch Illumination

1.0

805

Horn to Horn Button via Plug 2 Pin 9

1.0

809

Wash Switch to Wash Pump via Plug 2 Pin 10

1.0

810

Heater Switch to Resistor

1.0

811

Heater Switch to Resistor

1.0

812

Heater Resistor to Heater Blower

1.0

813

Flasher Relay to Indicator Switch via Plug 3 Pin 4

1.0

815

RH Indicator Switch to RH Indicator Rear via Plug 2 Pin 11

1.0

818

LH Indicator Switch to LH Indicator Rear via Plug 2 Pin 12

1.0

824

Side Light Switch to Rear Side Lights Splice

1.0

827

Front Working Light Switch to Switch Illumination

1.0

829

Brake Switch to Brake Solenoid via Plug 2 Pin 13

1.0

830

Brake Switch to Operational Solenoid via Plug 2 Pin 14.

1.0

831

Brake Switch Illumination

1.0

832

Auxiliary Hydraulic Switch to Splice (Fwd) via Plug 3 Pin 6.

1.0

834

Auxiliary Hydraulic Switch 1 Illumination

1.0

835

Auxiliary Hydraulic Switch 1 Illumination

1.0

836

Auxiliary Hydraulic Switch 1 to Splice via Plug 3 Pin 12

1.0

837

Auxiliary Hydraulic Switch 1 to Switch 2 via Plug 3 Pin 1

1.0

847

Switched Feed to Heated Seat

1.0

848

Link on Heated Seat Switch for Illumination

1.0

Section C

Electrics

9803/8500

Section C

7 - 3

Issue 1

Wire Number Identification

Summary of Contents for ROBOT 150

Page 1: ...VICE 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...

Page 2: ......

Page 3: ...s 2 Care Safety includes warnings and cautions pertinent to aspects of workshop procedures etc 3 Routine Maintenance includes service schedules and recommended lubricants for all the machine The remai...

Page 4: ...ge No Identifying your Machine 1 1 Torque Settings 2 1 Service Tools Numerical List 3 1 Electrics 4 1 Hydraulics 4 2 Sealing and Retaining Compounds 5 1 Section 1 General Information 9803 8500 Section...

Page 5: ...Year of Manufacture T 1996 1 2001 V 1997 2 2002 W 1998 3 2003 X 1999 4 2004 Y 2000 5 2005 Manufacturer Location E England Product Identification Number PIN Section 1 General Information 9803 8500 Sect...

Page 6: ...umber is stamped on the rear of the lift arm as shown at D 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...

Page 7: ...5 8 78 8 0 58 1 2 12 7 3 4 117 12 0 87 9 16 14 3 13 16 170 17 3 125 5 8 15 9 15 16 238 24 3 175 3 4 19 0 11 8 407 41 5 300 7 8 22 2 15 16 650 66 3 480 1 25 4 11 2 970 99 0 715 11 4 31 7 17 8 1940 198...

Page 8: ...Test Block Husco 4 3 892 00253 Pressure Test Kit 4 2 892 00255 Pressure Test Adapter 4 2 892 00256 Pressure Test Adapter 4 2 892 00257 Pressure Test Adapter 4 2 892 00258 Pressure Test Adapter 4 2 89...

Page 9: ...ools 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 0...

Page 10: ...nt 892 00268 Flow Monitoring Unit 892 00269 Sensor Head 0 100 l min 0 22 UK gal min 892 00270 Load Valve 1406 0021 Bonded Washer 1604 0006 Adapter 3 4 in M x 3 4 in M BSP 1612 0006 Adapter 3 4 in F x...

Page 11: ...General Information 9803 8500 Section 1 4 3 Issue 5 Service Tools Hexagon Spanners for Ram Pistons and End Caps 992 09300 55 mm A F 992 09400 65 mm A F 992 09500 75 mm A F 992 09600 85 mm A F Male Ada...

Page 12: ...s 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 Male Cone Blanking Plug 816 00294 1 4 in BSP 816 00189 3 8 in BSP 816 00190 1 2 in BSP 816 00197...

Page 13: ...anaerobic adhesives and sealants 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...

Page 14: ...i Contents Page No Safety Notices 1 1 General Safety 2 1 Operating Safety 3 1 Maintenance Safety 4 1 Safety Decals 5 1 Section 2 Care and Safety 9803 8500 Section 2 i Issue 1...

Page 15: ...sts If proper precautions are not taken it is highly probable that the operator or others could be killed or seriously injured INT 1 2 1 WARNING Denotes a hazard exists If proper precautions are not t...

Page 16: ...ING Care and Alertness All the time you are working with or on the machine take care and stay alert Always be careful Always be alert for hazards INT 1 3 5 WARNING Clothing You can be injured if you d...

Page 17: ...thrown around inside the cab or thrown out of the machine and crushed You must wear a seat belt when using the machine Fasten the seat belt before starting the engine 2 2 1 9 WARNING Exhaust Gases Bre...

Page 18: ...he battery Do not smoke close to the battery Make sure there is good ventilation in closed areas where batteries are being used or charged Do not check the battery charge by shorting the terminals wit...

Page 19: ...oling system is pressurised when the engine is hot Hot coolant can spray out when you remove the radiator cap Let the system cool before removing the radiator cap To remove the cap turn it to the firs...

Page 20: ...d decals The decals and their attachment points are shown on the following pages Each decal has a part number printed on it use this number to order a new decal from your JCB distributor INT 3 3 3 WAR...

Page 21: ...5 2 Safety Decals cont d Section 2 Care and Safety 9803 8500 Section 2 5 2 Issue 2...

Page 22: ...Light Bulbs 7 3 Hydraulic System Checking the Fluid Level 8 1 Changing the Filter 8 1 Transmission Drive Chain Lubrication up to machine number 677999 9 1 Checking the Oil Levels 9 1 Changing the Oil...

Page 23: ...ter JCB Diesel engine 10 4 Draining the Fuel Filter Peugeot engine 10 6 Changing the Fuel Filter Element Peugeot engine 10 6 Draining the Fuel Filter JCB Diesel engine 10 7 Changing the Fuel Filter El...

Page 24: ...hium based No 2 consistency JCB Special MPL Grease Chain Case Fill to level plug Engine Oil API CE 15W 40 or API CC 10W 30 Section 3 Routine Maintenance 9803 8500 Section 3 1 1 Issue 6 ITEM CAPACITY F...

Page 25: ...g used engine oil 1 Avoid prolonged excessive or repeated skin contact with used engine oils 2 Apply a barrier cream to the skin before handling used engine oil 3 Note the following when removing engi...

Page 26: ...rocarbons in the fuel A high ratio of lightweight hydrocarbons can affect the combustion characteristics Low Temperature Fuels Special winter fuels may be available for engine operation at temperature...

Page 27: ...RATING HOURS ONLY Change Engine Stopped 1 Engine oil and filter 2 Hydraulic fluid filter 3 Fuel filter drain if necessary JCB Diesel engine only Note The engine is supplied with Running in oil This mu...

Page 28: ...unting bolts 5 Battery charge and condition 6 Valve clearances JCB Diesel engine only Change 1 Hydraulic fluid filter s 2 Fuel filter element Peugeot engine only 3 Air filter outer element EVERY 1000...

Page 29: ...4 Start the engine 5 Slowly lower the loader arm onto the safety strut Stop the movement immediately the weight of the arm is supported by the strut Note Extreme care must be taken when lowering the l...

Page 30: ...commended grease In the following illustrations the grease points are numbered Count off the grease points as you apply grease to each one Refit the dust caps after greasing Quickhitch Pivot Pins for...

Page 31: ...loader arms can drop suddenly and cause serious injury Before working under raised loader arms fit the loader arm safety strut 2 1 1 6 Lift and Compensating Ram Pivots for interval see Service Schedul...

Page 32: ...mpartment rear door Note Early machines were fitted with an external catch as shown at X later machines have a concealed catch as shown at Y From September 1996 the door latch is as shown at Z Throttl...

Page 33: ...er 677999 Switch off the engine and ensure it cannot be started while you are doing this job Tilt the Safety Restraint forward and remove the seat Oil the joints of the control linkages A Section 3 Ro...

Page 34: ...678000 Switch off the engine and ensure it cannot be started while you are doing this job Raise the Safety Restraint and remove the seat Oil the joints of the control linkages A and B where fitted Sec...

Page 35: ...arter key 4 If necessary remove the floor plate in front of the operator s seat by unscrewing the four bolts securing it to the chassis 5 Loosen the blanking plates A from the ends of the chassis gutt...

Page 36: ...When disconnecting the battery take off the earth lead first When reconnecting fit the positive lead first Re charge the battery away from the machine in a well ventilated area Switch the charging cir...

Page 37: ...sary top up with distilled water 6 Refit battery cell cover s B 7 Refit the battery cover and latch WARNING Do not top up the battery with acid The electrolyte could boil out and burn you 2 3 4 6 WARN...

Page 38: ...nd 2 Ease the spring contact G to release the bulb 3 Fit new bulb Make sure the bulb is seated in the spring contact holes 4 Refit light unit F take care not to trap the wires Rotating Beacon Bulb 1 R...

Page 39: ...kets in the control panel 2 The bulb holders B can then be pulled from the back of the Switch Warning Lights and the bulbs will come with them 3 The bulbs C are a straight pull from the holder 4 Fit t...

Page 40: ...severely damaged if the machine is operated 3 If more fluid is needed wait for five minutes open the hydraulic tank filler cap C and top up with engine oil Changing the Filter for interval see Servic...

Page 41: ...right side of the machine Changing the Oil for interval see Service Schedule 1 Park the machine on level ground 2 Stop the engine 3 On the left side of the machine remove inspection plug A 4 Place a s...

Page 42: ...hine Changing the Oil for interval see Service Schedule 1 Park the machine on level ground 2 Stop the engine 3 On the left side of the machine remove one of the inspection cover bottom bolts A and its...

Page 43: ...move the rear wheel 5 Adjust the tension as described below a Loosen the six bolts B securing the hub locking ring C b Using a large adjustable spanner grip the lug on hub D rotate the hub until no fu...

Page 44: ...on for use in environments where a puncture could have serious consequences These tyres consist of a number of individual segments bolted to the wheel rim Damaged segments can be renewed individually...

Page 45: ...the canister Make sure they seat correctly by smearing the seals G and H with grease and checking for a witness mark on the canister base Fit and tighten nuts A and C 6 Make sure that the wire to the...

Page 46: ...ement E 4 Clean inside the canister G cover B and dust valve H 5 Insert the new elements into the canister pushing them firmly in so that seals F and J are fully seated Fit cover B with dust valve H a...

Page 47: ...sure the engine is cool before doing this job 2 3 3 2 This machine can be fitted with an engine oil drain plug kit This allows the oil to be safely changed when hot No special tools are needed 1 Do St...

Page 48: ...e oil 10 Screw in the new filter canister hand tight only 11 Fill the engine with the recommended oil to the MAX mark on the dipstick A through the filler point B Wipe off any spilt oil refit the fill...

Page 49: ...7 Close and secure the engine compartment hinged top cover and rear door Changing the Oil and Filter JCB Diesel engine for interval see Service Schedule WARNING Hot oil and engine components can burn...

Page 50: ...commended oil to the MAX mark on the dipstick A through the filler point B Wipe off any spilt oil refit the filler cap and make sure it is secure 12 Make sure the engine will not start by removing the...

Page 51: ...ng H 7 Separate element F bowl B and base G 8 Remove and discard seals J 3 off discard O ring L 9 Lubricate all seals and O rings with correct fuel oil 10 Fit new seals J 3 off to base G bowl B and el...

Page 52: ...iscard O ring L 9 Lubricate all seals and O rings with correct fuel oil 10 Fit new seals J 3 off to base G bowl B and element F fit O ring H to the centre of the element F 11 Fit element F bowl B base...

Page 53: ...protection is not needed This gives protection against corrosion and raises the coolant s boiling point WARNING Antifreeze can be harmful Obey the manufacturer s instructions when handling neat or dil...

Page 54: ...ller bottle using the necessary anti freeze solution 7 Refit the filler cap A 8 Check for leaks 9 Run the engine for a while to raise the coolant to working temperature and pressure Stop the engine an...

Page 55: ...ttery before doing this job 2 3 3 5 Adjusting the Alternator Belt 1 Loosen nut A and bolt B which secure the alternator 2 Adjust the fan belt by Peugeot engine turning bolt C to give 10 mm 3 8 in slac...

Page 56: ...he windscreen washer bottle A with a suitable liquid The liquid should contain a de icing fluid to prevent it freezing Do not use engine coolant antifreeze Section 3 Routine Maintenance 9803 8500 Sect...

Page 57: ...ction A Issue 3 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 dra...

Page 58: ...where it may be run over by a machine or otherwise crushed this will distort the coupling sleeve and prevent correct connection and disconnection DON T clamp on the smooth diameter of the coupling whe...

Page 59: ...rs to check for hydraulic fluid leaks Do not put your face close to suspected leaks Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid If hy...

Page 60: ...service see Section E Hydraulics WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin Do not use your fingers to check for hydraulic fluid leaks Do not put your face close to...

Page 61: ...ork itself It is not for the machine to which the fork may be fitted Before lifting any load check the weight of the load against the Safe Working Load of the machine 2 4 5 3 Daily Maintenance 1 Clean...

Page 62: ...e servicing see Section E Hydraulics WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin Do not use your fingers to check for hydraulic fluid leaks Do not put your face close...

Page 63: ...tor utilise an attachment frame for installation on a Skid Steer Loader Daily Maintenance 1 Clean with the rest of the machine 2 Check for damage Repair or replace as necessary S204170 Section A Optio...

Page 64: ...ours Slacken locking nuts A and then tighten studs B until there is no play Tighten the locking nuts firmly Technical Data Main Relief Valve MRV 172 bar 2494 lbf in2 Auxiliary Relief Valves Boom raise...

Page 65: ...re to opposite ends of the two rams to create a push pull effect which swings the boom As the ram pistons move along their bores exhaust oil is directed to tank via the exhaust gallery Relief Valves a...

Page 66: ...up and off the control levers 3 Disconnect all the hoses from the valve block making sure to identify their mounting positions for replacement purposes Cap the ports and hoses to prevent the ingress o...

Page 67: ...hments Section A Section A 7 4 7 4 9803 8500 Issue 1 Valve Block Dismantling and Assembly Backhoe C L F 6 5 4 3 2 1 B G G Z Z Y Y X X H H X X Y Y Z Z J J L L C C E E A A K K F F E E D D W W V V B B S2...

Page 68: ...are not fitted and the lever engages a detent to positively hold it ON and OFF In position H on the rockbreaker segment a pre assembled pressure release cartridge is installed Do not confuse with the...

Page 69: ...om raise service 5 Adjust ARV D to operate at 180 bar 2610 lbf in2 6 Reset the MRV to its normal operating pressure see Main Relief Valve 7 Disconnect locking stay B and stow it as shown by the dotted...

Page 70: ...eve circuit pressure by operating the backhoe controls a few times If the backhoe is detached from the Robot Skid Steer make sure the carriage clamp lever is in the released position The numerical seq...

Page 71: ...raulic pipes followed by the two 90 elbow connectors located at the top of the inboard face A of stabiliser sleeve B from the stabiliser ram pipework 4 Dismantle items 1 to 7 in sequence Note After re...

Page 72: ...Attachments Section A Section A 7 9 7 9 9803 8500 Issue 1 Dipper and Boom Removal and Replacement Backhoe D E L M J K F G H L N S P R A C B A...

Page 73: ...uipment support the weight of the dipper at its boom end Loosen lock nuts F and then back off studs G from swivel pin H Remove the pivot pin 9 Lift the dipper clear of the boom 10 Replacement is the r...

Page 74: ...Attachments Section A Section A 7 11 7 11 9803 8500 Issue 1 Rams Backhoe G H K L G J C D K M B A E F 6 5 4 3 2 1 7 1218...

Page 75: ...y Lower the boom onto blocks so that the bucket is just clear of the ground Lower the dipper until the bucket rests on the ground 2 Switch off the engine and operate the backhoe controls to relieve sy...

Page 76: ...sure that the end cap is securely fitted Severe injury can be caused by a suddenly released piston rod HYD 1 2 Remove and discard seals 6 to 12 Assembly Assembly is the reverse of dismantling Fit new...

Page 77: ...Attachments Section A Section A 7 7 9803 8500 Issue 1 Backhoe...

Page 78: ...emoval and Replacement 1 1 Glazing Front Window Removal and Replacement 3 1 Rear window Removal and Replacement 3 2 Side Window Removal and Replacment 3 4 Door Removal and Replacement 4 1 Loader Arm R...

Page 79: ...iding the seat out of its runners and away from the hinges 3 on the floor plate Replacement Replacement is a reversal of the removal procedure Floor Plate To carry out major work on the hydraulics suc...

Page 80: ...e engine 2 Remove the windscreen wiper blade 3 Remove the front screen as follows a Remove the three wingnuts D inside the cab b Remove the securing plates E outside the cab c Carefully lift the front...

Page 81: ...3 2 Rear Window Section B Body and Framework 9803 8500 Section B 3 2 Issue 1 Glazing 1 1 2 2 3 3 4 4 5 5 6 6 7 7 137770...

Page 82: ...o the seal using a glazing tool Part No 992 01100 as shown DO NOT USE FORCE 5 Remove the hook from the glazing tool and fit the correct size eye for the filler strip Thread the filler strip through th...

Page 83: ...3 4 Side Windows Section B Body and Framework 9803 8500 Section B 3 4 Issue 1 Glazing 136161 1 1 2 2 3 3 4 4...

Page 84: ...t Replacement 1 Fit the glazing seal around the edge of glass 2 Wind string around the seal Pull string tight to compress the inner seal Apply soap to the seal 3 Place the glass into the frame from ou...

Page 85: ...of the machine Removal 1 Remove one end of the door s gas strut 2 Open the door fully and lift from the hinges Replacement Replacement is a reversal of the removal procedure Section B Body and Framew...

Page 86: ...5 1 Section B Body and Framework 9803 8500 Section B 5 1 Issue 1 Loader Arm 167760 Z Z B B A A X X Y Y...

Page 87: ...in the diagram Take the weight of the arm on the lifting equipment Let all hydraulic pressure decay from the system or crack the pipe connections Disconnect all hydraulic lines to the loader arm and...

Page 88: ...ion 4 1 Service Precautions 4 1 Charging Circuit check 4 1 Alternator Charging Test 4 2 Removal and Replacement Peugeot Engines 4 2 Perkins Engines 4 4 Dismantling Assembly 4 4 Starter Motor Starting...

Page 89: ...nes JCB Diesel Engines Light Bulbs Working Lights Indicator Lights Interior Light Warning Light Beacon if fitted Side Lights Section C Electrics 9803 8500 Section C 1 1 Issue 5 Technical Data 12 Volts...

Page 90: ...ection C Electrics 9803 8500 Section C 1 2 Issue 3 Technical Data 174511 Fuse Canopy Machine Cab Machine Options Fuse Size Number 1 Spare Interior light Front work lights 10 amp 2 Spare Beacon Rear wo...

Page 91: ...er fuse board X only fuse boards X and Y 1 Interior light Beacon 10 amp Interior light Roadlights 15 amp 2 Front and rear working lights 15 amp Beacon 10 amp 3 Interlock relay Brake solenoid 5 amp Int...

Page 92: ...the red socket marked with V or 2 Ensure that the test probes have a good clean contact with bare metal free from grease dirt and corrosion as these can cause a false reading 3 When measuring voltage...

Page 93: ...y low resistance between two points the needle will move across fully or almost fully to the right hand side of the scale How to Test a Diode or a Diode Wire A diode wire is a diode with male and fema...

Page 94: ...ts Fault Diagnosis Battery Tester Readings 1 CHECK 0 12 6 Volts LOAD less than 6 Volts 2 CHECK 6 12 4 Volts LOAD less than 9 Volts and falls steadily but remains in yellow zone 3 CHECK less than 10 Vo...

Page 95: ...rnator connections are in place secure and making good metal to metal contact especially the earth connections to chassis and engine Adjust the alternator drive belt tension if necessary and make sure...

Page 96: ...s failure of the alternator Service Procedures See page C 4 3 Removal and Replacement Peugeot Engines Disconnect the battery negative lead Disconnect the wiring from the rear of the alternator Loosen...

Page 97: ...4 3 Section C Electrics 9803 8500 Section C 4 3 Issue 1 Alternator S213570...

Page 98: ...ing end bracket 8 Carefully remove rectifier 10 and stator 11 as an assembly Unsolder the interconnecting wires at X Y and Z only if renewing either of these components Remove nut and washer 12 using...

Page 99: ...fault in the wiring from the start relay to the solenoid If the reading between terminal D and earth is below 8 0 V connect the voltmeter between terminal E and earth An increase in the reading to 8...

Page 100: ...cedure Torque Settings Securing bolts C 34 Nm 25 lbf ft 3 5 kgf m Service Procedures Servicing this equipment is not recommended Should faults occur then the starter motor should be changed for a Serv...

Page 101: ...Motor 2 53 Reverse Alarm Switch 1 3 54 Reverse Alarm Switch 2 3 55 Reverse Alarm Buzzer 3 56 Brake Light Pressure Switches 4 Lamps Option 70 Pre heat Warning 1 71 Interior Light 3 72 Right Hand Front...

Page 102: ...9 614 613 27 29 400 405 401 412 413 414 418 424 605 403 402 409 411 416 417 420 407 628 610 629 609 404 401 408 415 419 406 835 836 832 834 837 25 24 23 20 22 839 838 641 640 635 21 631 634 829 830 63...

Page 103: ...832 834 837 25 23 20 839 838 641 640 635 634 829 830 633 805 6 11 9 5 4 27 2 14 7 3 G M A206390 10 114 115 11 12 100 101 44 31 804 803 22 21 116 117 54 121 120 53 52 51 50 48 49 45 92 94 35 36 41 118...

Page 104: ...h 1 2 55 Reverse Alarm Switch 2 2 56 Reverse Alarm Buzzer 2 57 Float Solenoid 2 Lamps Option 70 Pre heat Warning 1 71 Interior Light 2 72 Left Hand Side Light Rear 2 73 Right Hand Side Light Rear 2 74...

Page 105: ...c Oil Temperature Switch 1 26 Engine Oil Pressure Switch 1 27 Engine Water Temperature Switch 1 28 Air Cleaner Warning Switch 1 29 Low Fuel Warning Switch 1 30 Engine Shut Off Solenoid 1 31 Float Sole...

Page 106: ...YDRAULIC OIL TEMP ENGINE OIL PRESSURE WATER TEMP SWITCH AIR CLEANER LOW FUEL E S O S FLOAT SOLENOID HORN EQUIPMENT OPTIONS STANDARD OPTIONAL 246 90901 BATTERY AUX NEUTRAL START RELAY START SOLENOID GL...

Page 107: ...H DIP BEAM RH DIP BEAM ITALIAN GERMAN LH TAIL LIGHT RH TAIL LIGHT LH SIDE LIGHT RH SIDE LIGHT NO PLATE LIGHT HEATED SEAT BATTERY AUX NEUTRAL START RELAY START SOLENOID STARTER SWITCH GLOW PLUG RELAY R...

Page 108: ...Hydraulics Solenoid Valve 0 Y 17 High Flow Hydraulics Switch 0 Y Lamps Option 70 Interior Light 1 Y 71 L H Dip Beam Italian 0 Y 72 R H Dip Beam Italian 0 Y 73 L H Dip Beam German 0 Y 74 R H Dip Beam...

Page 109: ...reen Washer 1 Y 50 Screen Washer Switch 1 Y 51 Front Wiper 1 Y 52 Front Wiper Switch 1 Y 53 Reverse Alarm Switches 1 Y 54 Reverse Alarm Buzzer 1 Y 55 Heater Switch 1 Y 56 Heater Blower Resistance 1 Y...

Page 110: ...GHT RH BRAKE LIGHT LH FRONT INDICATOR RH FRONT INDICATOR LH REAR INDICATOR RH REAR INDICATOR REAR WIPER FRONT WIPER SCREEN WASHER FRONT HEATER MOTOR PRESS SWITCH LATCHING RELAY FLOAT SWITCH BRAKE LIGH...

Page 111: ...FUEL E S O S HORN 5 STARTER SWITCH GLOW PLUG RELAY FRONT WORK LIGHT SW REAR WORK LIGHT SW BRAKE SWITCH INTERLOCK RELAY ENGINE EARTH 6 7 8 9 10 11 11 12 14 15 16 17 18 21 22 23 24 25 26 27 28 29 30 35...

Page 112: ...ch 1 28 Air Cleaner Warning Switch 1 29 Low Fuel Warning Switch 1 30 Engine Shut Off Solenoid 1 31 Float Solenoid 0 32 Pressure Switch 0 33 Latching Relay 0 34 Float Switch 0 35 Horn 1 36 Horn Push 1...

Page 113: ...Relay 1 Lamps Option 60 Interior Light 1 Y 61 L H Dip Beam Italian 0 Y 62 R H Dip Beam Italian 0 Y 63 L H Dip Beam German 0 Y 64 R H Dip Beam German 0 Y 65 L H Rear Light 0 Y 66 No Plate Light 0 Y 67...

Page 114: ...TAIL LIGHT RH TAIL LIGHT LH SIDE LIGHT RH SIDE LIGHT NO PLATE LIGHT HEATED SEAT BATTERY STARTER SOLENOID AUX NEUTRAL ST RELAY STARTER SWITCH GLOW PLUG RELAY ROADLIGHT SWITCH INTERLOCK RELAY BRAKE SWI...

Page 115: ...AIR CLEANER LOW FUEL HORN E S O S LH FRONT INDICATOR RH FRONT INDICATOR LH REAR INDICATOR RH REAR INDICATOR REAR WIPER FRONT WIPER SCREEN WASHER FRONT HEATER MOTOR ENGINE EARTH 246 91502 2 OF 2 SLOW F...

Page 116: ...42 Reverse Alarm Switches 1 Y 43 Reverse Alarm Buzzer 1 Y 44 Heater Blower 1 Y 45 Heater Blower Resistance 1 Y 46 Heater Switch 1 Y 47 Engine Earth 1 Lamps Option 71 Alternator Warning 1 72 Charge Pu...

Page 117: ...ng wire identification 1 Wires will continue to have the same number even after passing through a bulkhead connector into a different harness 2 The wire number categories shown in the tables on the fo...

Page 118: ...0 Neutral Start Relay to Start Solenoid 1 0 31 From Diode to Splice S l 1 0 32 Signal from Auxiliary Hydraulic Switch 1 0 33 Signal from Auxiliary Hydraulic Switch 1 0 35 From Diode to S l Splice 1 0...

Page 119: ...h to Rear Working Light Switch Earth 1 0 632 Brake Switch to Earth Splice SM 1 0 635 Auxiliary Hydraulic Switch Earth to Earth Splice SA 1 0 638 Earth Splice to Earth SM via Plug 2 Pin 6 2 0 639 Earth...

Page 120: ...Switch 1 0 417 Low Fuel Warning Light to Switch 1 0 420 Hydraulic Oil Pressure Warning Light to Switch 1 0 421 Reverse Alarm to Switch 1 0 422 Reverse Alarm Switch 1 to Switch 2 1 0 425 Flasher Relay...

Page 121: ...y Hydraulic Forward to Splice 1 0 Front Roof Harness Wire No Wire Function Size mm 12 Front Wiper to Panel Harness 1 0 21 Door Switch to Panel Harness 1 0 22 Door Switch to Panel Harness 1 0 600 Earth...

Page 122: ...1 Locking Mechanism Removal and Replacement 1 1 Adjustment 1 1 Throttle Controls Description 2 1 Removal and Replacement 2 1 Adjustment 2 1 Throttle Cable Removal and Replacement 2 3 Adjusting the Id...

Page 123: ...1 1 Section D Controls 9803 8500 Section D 1 1 Issue 1 Safety Restraint Bar S168160 1...

Page 124: ...traint bar 5 in the direction of the arrow X towards the left hand side of the machine 4 The restraint bar can now be lifted from the machine Take care to recover bushes 6 and washers 7 5 To remove ca...

Page 125: ...2 1 Section D Controls 9803 8500 Section D 2 1 Issue 1 Throttle Controls S168150D...

Page 126: ...when the foot throttle is released the engine speed reverts to that set by the hand control The hand throttle alone is shown at B Removal Disconnect the hand throttle cable at C then remove bolts 4 of...

Page 127: ...ling Settings Engine warm Loosen the nut 9 and deceleration screw 8 so that the latter protrudes 13 to 14 mm from the face of the regulator casing Unlock locknut 5 and start the engine With the fast i...

Page 128: ...emoval and Replacement 9 1 Pump Engine Couplings 9 2 Start Up Procedure 9 3 Hydrostatic Pump servo up to machine no 676354 and manual Dismantling and Assembly Trunnion Covers 10 1 Shaft Seal 10 1 Chec...

Page 129: ...ief Valves Removal Replacement Dismantling and Assembly 16 5 Pressure Testing Main Relief Valve 16 6 Pressure Testing Auxiliary Relief Valve 16 7 Loader Valve from machine number 677001 Dismantling an...

Page 130: ...number 675574 to 677000 30 3 Servo machines from serial number 677001 to 677999 Single Drive Lever Control 30 5 Dual Drive Lever Control 30 7 Manual machines from serial number 677001 to 677999 30 9 S...

Page 131: ...ype 57 l min 12 5 UK gal 15 US gal min at 3600 rev min 90 l min 19 8 UK gal 23 8 US gal min at 3600 rev min 185 192 bar 2683 2785 lbf in2 188 196 kgf cm2 3600 rev min 121 Nm 89 lbf ft 12 kgf m Tandem...

Page 132: ...High Flow Suction Strainer 185 192 bar 2683 2785 lbf in2 188 196 kgf cm2 20 bar 290 lbf in2 20 kgf cm2 Boom Ram Hydraulic Servo Crowd Raise Lower Hydraulic Servo Auxiliary Electrical Solenoid 35 cc mi...

Page 133: ...mpensating 60 x 30 50 x 25 Bore Rod Dia Stroke mm in mm in mm in 70 2 75 40 1 57 677 26 65 80 3 15 40 1 57 233 9 17 100 3 94 50 1 97 234 9 21 60 2 36 30 1 18 264 10 39 50 1 97 25 0 98 288 11 32 Nm lbf...

Page 134: ...rev min Dual gear type 48 l min 10 5 UK gal 12 7 US gal min at 3000 rev min 106 l min 23 3 UK gal 28 US gal min at 3000 rev min 207 bar 3002 lbf in2 211 kgf cm2 3000 rev min Tandem axial piston Series...

Page 135: ...e Electrics Filter Type Main Hydraulic High Flow Suction Strainer 207 bar 3002 lbf in2 211 kgf cm2 20 bar 290 lbf in2 20 kgf cm2 Shovel Ram Hydraulic Servo Boom Ram Hydraulic Servo Auxiliary Electrica...

Page 136: ...mpensating 60 x 30 50 x 25 Bore Rod Dia Stroke mm in mm in mm in 70 2 75 40 1 57 677 26 65 80 3 15 40 1 57 233 9 17 100 3 94 50 1 97 234 9 21 60 2 36 30 1 18 264 10 39 50 1 97 25 0 98 288 11 32 Nm lbf...

Page 137: ...00 rev min Dual gear type 54 l min 11 9 UK gal 14 2 US gal min at 3000 rev min 106 l min 23 3 UK gal 28 US gal min at 3000 rev min 207 bar 3002 lbf in2 211 kgf cm2 3200 rev min Tandem axial piston Ser...

Page 138: ...Electrics Filter Type Main Hydraulic High Flow Suction Strainer 207 bar 3002 lbf in2 211 kgf cm2 20 bar 290 lbf in2 20 kgf cm2 Shovel Ram Hydraulic Servo Boom Ram Hydraulic Servo Auxiliary Manually op...

Page 139: ...machines prior to serial number 678000 hydraulic pressure for the joysticks is regulated by the Pressure Reducing Solenoid Valve which together with its associated electrical circuitry is designed to...

Page 140: ...particles etc 2 Liquid usually water and incompatible oils and greases 3 Gases Air sulphur dioxide etc which can create corrosive compounds if dissolved in the fluid These contaminants can appear dur...

Page 141: ...tion strainer S1 The pump P3 delivers pressurised oil to the pressure reducing solenoid valve R and to the loader control valve L In the neutral position valve R returns the oil into the suction line...

Page 142: ...Hydraulics 9803 8500 Issue 1 4 1 4 1 Descriptions Section E Section E...

Page 143: ...tween the gear teeth and the pump body As the gears come into mesh the oil is forced out through the outlet port Some oil is allowed to circulate behind the bearings C to hold them against the gears a...

Page 144: ...flows past the main relief valve 6 and on to feed the main pumps and directional joystick via outlet line 2 Oil trapped in the lines prevents movement of the rams Oil also fills the parallel gallery...

Page 145: ...Hydraulics 9803 8500 Issue 2 5 2 5 2 Descriptions Section E Section E...

Page 146: ...Hydraulics 9803 8500 Issue 2 5 3 5 3 Descriptions Section E Section E...

Page 147: ...spool is not selected instead it flows to the crowd ram 5 This has the effect of causing the crowd ram to close in proportion to the loader arm movement automatically keeping the shovel parallel to t...

Page 148: ...s Oil from the other side of the ram returns to the exhaust line via the control valve At the same time pressure is applied to the compensating ram 3 But since the lift ram 4 is locked as the lift spo...

Page 149: ...Hydraulics 9803 8500 Issue 2 5 6 5 6 Descriptions Section E Section E...

Page 150: ...llustration shows arms raise being selected by the lift ram spool 1 The weight of the loaded shovel as indicated by the arrows causes a higher pressure in the service line than in the parallel gallery...

Page 151: ...eutral circuit has been blocked by the central lands of the selected spool 1 the pressure in parallel gallery X increases until it is greater than that in the service line At this point the load hold...

Page 152: ...Hydraulics 9803 8500 Issue 1 5 9 5 9 Descriptions Section E Section E...

Page 153: ...ween the upper and lower surfaces of piston F causes this piston to rise and seat on the point of pilot poppet A Oil continues to escape from the cavity E but the incoming flow to the cavity has been...

Page 154: ...2 21 631 634 829 830 632 633 112 14 15 18 19 29 29 16 17 78 831 PRESSURE IN JOYSTICK LOADER TANK BRAKE SOL 14 17 SOL 13 16 Z X Y 1 2 3 4 EXTRACTS FROM THE WIRING DIAGRAM SCHEMATICS 23 20 634 829 830 6...

Page 155: ...nes manufactured after May 1996 This valve controls the Safety Restraint Bar circuit the door latch circuit brake circuit and pressure reduction circuit It contains a reducing valve cartridge and a 3...

Page 156: ...Output Shaft B Brake Pack C Cardan Shaft D Gearwheel Set E Valve Drive F Disc Valve Oil under pressure passes through the disc valve inlets to the inter tooth chambers on one side of the gearwheel se...

Page 157: ...ith oil from auxiliary pump P being applied to the brake pack via shuttle valve E which is part of the pressure reducing valve and port C on the motor casing When the brake is selected to the on condi...

Page 158: ...N OPERATION NEUTRAL With the engine running but no drive selected oil from pump P3 is fed through the loader valve 2 and filter F1 to main pumps P1 and P2 A small amount of oil flows through the charg...

Page 159: ...s P1 and P2 The swash plates are tilted causing flow to pass to the motors M1 and M2 and the machine moves forward Return oil from the motors flows back into the main pumps Any excess oil from the pum...

Page 160: ...it can be lifted clear Note A special tool Part No 993 99510 is required to remove the bottom flange bolt D Replacement Using suitable lifting tackle ease the pump unit into position making sure that...

Page 161: ...ump unit is bolted The outer coupling B is bolted to the engine with four capscrews E The inner section A is tightened onto the pump shaft spline with cap screw D Coat threads of capscrew D with JCB T...

Page 162: ...medical help immediately INT 3 1 10 1 Fill the hydraulic tank with the correct fluid see page 3 1 1 via a 10 micron filter no by pass Check that the pump inlet line from the hydraulic filter to the pu...

Page 163: ...10 1 Section E Hydraulics 9803 8500 Section E 10 1 Issue 1 Pumps 168150...

Page 164: ...Carefully remove the seal cover 7 Take care not to damage the shaft or housing Remove the O ring 8 from the seal cover and discard Press out the seal 9 from the seal cover 7 using an arbor press and...

Page 165: ...10 3 Section E Hydraulics 9803 8500 Section E 10 3 Issue 1 Pumps 168030...

Page 166: ...essure checking and adjustment If the charge pressure relief valve has been dismantled it will require setting up as follows 1 Install a 0 35 bar 0 500 lb in2 0 35 kg cm2 pressure gauge in the pressur...

Page 167: ...10 5 Section E Hydraulics 9803 8500 Section E 10 5 Issue 1 Pumps 168160...

Page 168: ...econd pump is a mirror image of this Protect all exposed sealing surfaces and open cavities from damage and foreign material Mark the position of control linkage 33 before removing it from the swash p...

Page 169: ...t screw C A A C C B B D D This condition may be corrected by adjusting the pump servo units but before attempting this carry out the following preliminary checks Check tyre pressures The pressure of o...

Page 170: ...uring that no load is applied to the bracket Make sure that the dowelled bracket under locknut E is correctly located into the side plate J and into the engine bell housing Start the engine and allow...

Page 171: ...d Such a procedure is outside the scope of this Service Manual 3 Remove O ring 5 from seal carrier 3 Discard the O ring 4 Using a suitable press press out lip seal 6 from the seal carrier Discard the...

Page 172: ...ure Relief Valve is factory set and cannot be repaired 3 Remove and discard O rings 3 and 4 and back up ring 5 from plug 1 4 Inspect relief valve 2 and mating seat in plug 1 for damage Replace if nece...

Page 173: ...into pump body to align with the marks made during disassembly Tighten the locknut 8 Check the charge pressure and adjust as necessary Charge Pressure Checking and Adjustment 1 Stop engine Connect a...

Page 174: ...ne 3 Remove the floor plates 4 Loosen locknut A and turn the neutral adjusting screw B 1 10 of a turn in the required direction then re tighten the locknut If the wheels are creeping forward turn the...

Page 175: ...11 1 Section E Hydraulics 9803 8500 Section E 11 1 Issue 2 Pumps 167750...

Page 176: ...wed vice with the sealing rings facing upwards and assemble the body 3 Ensure that the body cut in track corresponds to the inlet side of the flange Assemble the gear bearing pack components 4 5 6 and...

Page 177: ...11 3 Section E Hydraulics 9803 8500 Section E 11 3 Issue 1 Pumps 291090 2 7 A 6 4 5 8 9 10 3 X 11 12 17 16 14 15 18 19 20 13 22 21 1...

Page 178: ...bores of the bearing blocks 6 8 16 and 18 which are coated during manufacture with PTFE If the grey PTFE is worn through so that the bronze base is visible the complete pump must be renewed Renew pum...

Page 179: ...13 1 Section E Hydraulics 9803 8500 Section E 13 1 Issue 1 Drive Motors 167720 S167720A...

Page 180: ...ydraulic hoses from the motors A Plug exposed connections Withdraw capscrews B The motors can now be lifted clear Replacement Replacement is the reversal of the removal procedure Renew all seals and O...

Page 181: ...13 3 Section E Hydraulics 9803 8500 Section E 13 3 Issue 2 Drive Motors S167730 A A B S167730B S167730A...

Page 182: ...d in the same relative positions Assembly Before assembling lubricate all parts with oil Grease all seals and O rings with Vaseline Ensure bearing 44 is pressed fully onto the shoulder of shaft 29 Soa...

Page 183: ...13 5 Section E Hydraulics 9803 8500 Section E 13 5 Issue 1 Drive Motors S243720 X X S243870...

Page 184: ...O ring 73 Unscrew capscrews 74 in a progressive manner then remove end cover 64 from brake housing 60 Remove and discard gasket 70 Withdraw spring disc 78 from brake housing 60 Insert a suitable bolt...

Page 185: ...Grease Carefully press bearing cup 7 into the front casing Position drive shaft 1 vertically on a press Warm bearing cone 8 and press into position on the shaft Pack the front bearing cone with JCB HP...

Page 186: ...or pressure incorrect Check tyre pressures and condition 3 9 4 4 Charge pressure incorrect Adjust charge pressure E10 3 E10 11 5 No or low pump output Check pump carry out wheel speed check E14 4 If...

Page 187: ...erative Check joystick plunger movement leaking seals etc E20 3 21 Chain tension Check chain tension 3 9 3 F1 6 22 Motor failure Inspect motor for damage Repair as required E13 3 E13 5 23 Spider type...

Page 188: ...wop the motor feed hoses from one side to the other as indicated in the illustrations i e swop hoses A and D then swop hoses B and C 5 Restart the engine and re check the operation of left and right m...

Page 189: ...Diagram X shows servo pump up to machine no 676354 Illustration Y shows servo pump from machine no 676355 2 If the left hand wheels are rotating too fast in forward or reverse screw in adjusters B fo...

Page 190: ...A D D C C B B This condition may be corrected by adjusting the pump servo units but before attempting this carry out the following preliminary checks Check tyre pressures The pressure of one tyre may...

Page 191: ...ws are set to allow a gap when the servo piston is at full travel Therefore to limit piston travel it is necessary to screw in the adjuster screws to eliminate the gap before adjustment can take place...

Page 192: ...ate lever cover to gain access to the lever stop Stop the engine and remove the starter key whilst the adjustment is made If the machine is veering to the right slacken locknut B on the left hand cont...

Page 193: ...essure generated in the motor feed line see next page for pressure test points 6 Start the engine and with the parking brake ON operate the motor service Measure the amount of oil expelled from the mo...

Page 194: ...otor feed pressure test points A Left motor front port B Left motor rear port C Right motor rear port D Right motor front port Note Point D on the Series 40 pump illustration X is on the right side of...

Page 195: ...lear of the ground Stop the engine Ensure the machine is stable 2 Remove the seat and floorplate to access the pressure test point A Note Illustration X shows motors up to machine no 677999 Illustrati...

Page 196: ...which should show the main pump charge pressure see Hydraulics Technical Data Section E Hydraulics 9803 8500 Section E 14 11 Issue 1 Problem Solving 5 If the gauge shows no or little pressure it coul...

Page 197: ...16 1 Section E Hydraulics 9803 8500 Section E 16 1 Issue 2 Valves S167681 D D B B C C A A F F E E D D E E F F D D B B E E A A C C C C C C C C S267990...

Page 198: ...e that all pressure has gone Drain the hydraulic tank 1 Disconnect the hydraulic inlet at A and the outlet at B Cover exposed connections to prevent ingress of dirt 2 Remove the hoses from the work po...

Page 199: ...16 3 Section E Hydraulics 9803 8500 Section E 16 3 Issue 3 Valves S167672 1 2 3 4 5 6 7 9 8 10 9 8 12 11 12 11 12 11 12 11 13 13 14 15 16 17 18 18 19 21 20 21 20 18 23 22 C D E F G A B...

Page 200: ...om individual sections 7 Carefully push out the check valve 15 and spring 16 Push out the spool 17 Only spool E is described but F and G are the same 8 Remove the auxiliary relief valves 18 1 from E 2...

Page 201: ...rers do not recommend renewing individual components of the M R V or A R V s Each valve should be renewed as a unit if a component is defective Renew all O rings Lubricate parts with JCB Special Hydra...

Page 202: ...ully open or closed and noting the maximum gauge reading Keep clear of the loader arm The maximum pressure should be as stated in Technical Data If the pressure is incorrect remove dome nut B slacken...

Page 203: ...plugs 892 00059 and bonded washers 1406 0021 Pressurise until oil begins to escape from the drain hole D At this point the gauge will indicate the crack pressure of the A R V The pressure should be a...

Page 204: ...16 8 Section E Hydraulics 9803 8500 Section E 16 8 Issue 2 Valves 1 2 3 4 5 6 7 6 8 9 10 11 11 12 12 13 14 15 16 16 16 16 17 17 18 19 20 21 22 23 24 25 26 30 27 28 29 316950 316960 X...

Page 205: ...ons individually Do not interchange parts from individual sections 7 Remove check valve guide 18 spring 19 and poppet 20 Note that the check valves are secured in position by one of the tie rods 8 Rem...

Page 206: ...inset Apply a force of 84N 19 lbf on the cup to compress the spring then measure distance A which should be 5 08 mm 0 2 in Add shims under the spring or replace the spring as necessary Assembly Assemb...

Page 207: ...lve Note Work on the operation sections individually Do not interchange parts from individual sections 5 Clean all parts in kerosene inspect and check for damage Damaged sections should be replaced co...

Page 208: ...imited to replacing the three O ring seals two on the valve cartridge and one on the cap The seal on the piston is not serviceable if this or any other part of the valve is damaged the complete valve...

Page 209: ...lowering the loader arm until the rams are fully open or closed and noting the maximum gauge reading Keep clear of the loader arm The maximum pressure should be as stated in Technical Data If the pres...

Page 210: ...0 422 kg cm2 pressure gauge to the pressure port P Pressurise until oil begins to escape from the drain hole T At this point the gauge will indicate the crack pressure of the A R V The pressure should...

Page 211: ...dy C The minimum opening pressure is 8 bar 116 lbf in2 To adjust the opening pressure screw plug A in or out of the body C as required If the valve is damaged or worn replace as a unit Do not fit part...

Page 212: ...18 1 Section E Hydraulics 9803 8500 Section E 18 1 Issue 2 Valves S204980 X X 3 B A 4 2 1 5...

Page 213: ...as necessary Assembly Assembly is a reversal of the dismantling procedure Fit new O ring seals Torque tighten to 23 28 Nm 17 21 lbf ft 2 3 2 9 kgf m Check and if necessary adjust the setting of cartri...

Page 214: ...iner 11 and spool 12 Inspect the spool and spool bore for signs of wear nicks scratches etc Assembling Assembly is the reversal of the dismantling procedure Renew all O rings Lightly lubricate all par...

Page 215: ...20 1 Section E Hydraulics 9803 8500 Section E 20 1 Issue 1 Servo Joysticks S167960...

Page 216: ...f pressurised hydraulic oil and wear protective glasses HYD 4 3 Mark the joystick flange and supporting flange at 1 to ensure correct realignment on replacement Remove the hydraulic flexible hoses at...

Page 217: ...20 3 Section E Hydraulics 9803 8500 Section E 20 3 Issue 1 Servo Joysticks 167950...

Page 218: ...dy Do not mix components from different valve units A Handle assembly used on the loader control joystick Assembly Lubricate all parts with hydraulic fluid before assembly O rings and seals should be...

Page 219: ...Arm Removal up to but not including the point at which the loader arm pivot pins are removed Disconnect the lift ram and or the compensating ram at A B as described in that procedure Remove the rear...

Page 220: ...ressure is released from the system WARNING Hydraulic Pressure It is not possible to vent all residual pressure Loosen the connection one full turn and allow the pressure to dissipate Keep face and ha...

Page 221: ...23 3 Section E Hydraulics 9803 8500 Section E 23 3 Issue 1 Rams S167800...

Page 222: ...6 Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker Note Threadlocker and Activator must not contact seals bearing rings or O rings Apply JCB Threadlocker Sealer High Stre...

Page 223: ...003 1 Stop the engine and wait for 5 minutes 2 Open the engine compartment rear door 3 Loosen the hydraulic filler cap and allow the pressure to dissipate then remove the cap 4 Drain the hydraulic oil...

Page 224: ...screw plug A to drain the tank Note Always drain into a suitable container 2 Unscrew bolts B remove cover plate C together with its gasket 3 Unscrew and remove the main suction strainer which is screw...

Page 225: ...J Attachment Auxiliary Relief Valve if required 2X Pressure Test Points Hand Pump Connectors 3 Check Valve 8 bar 4 Oil Cooler By pass Valve 2 bar 5 Lift Ram 5A Manually Operated Dump Valve 6 Compensat...

Page 226: ...Section E Section E Hydraulics 9803 8500 Issue 4 30 2 30 2 A167843 1 2 3 4 5 5A 6 7 F1 2X M1 P1 P2 M2 P3 8 T T S1 C 2X 9 2A 2B 2C 2D 2E 2F 2G 2X 10 2H 2J F2 S2 11 12 12A 13 14 2X Schematic Circuit...

Page 227: ...Section E Section E Hydraulics 9803 8500 Issue 2 30 3 30 3 A167845 1 2 3 4 5 5A 6 7 F1 2X M1 P1 P2 M2 P3 8 T T S1 C 2X 9 2A 2B 2C 2D 2E 2F 2G 2X 10 2H 2J F2 S2 11 12 12A 13 14 2X 2K Schematic Circuit...

Page 228: ...ed 2J Attachment Auxiliary Relief Valve if required 2K One way Restrictor 2X Pressure Test Points 3 Check Valve 8 bar 4 Oil Cooler By pass Valve 2 bar 5 Lift Ram 5A Manually Operated Dump Valve 6 Comp...

Page 229: ...2J Auxiliary Relief Valve ARV 2K One way Restrictor 2X Pressure Test Points 3 Drive Control Joystick 4 Check Valve 8 bar 5 Lift Ram 5A Manually Operated Dump Valve 6 Compensating Ram 7 Crowd Ram 8 Pre...

Page 230: ...ction E Section E Hydraulics 9803 8500 Issue 3 30 6 30 6 A257392 1 2 3 4 5 6 7 F1 2X M1 P1 P2 M2 P3 8 5A T T S1 C1 2X 9 2A 2B 2C 2D 2E 2F 2G 2X 10 2H 2J F2 S2 11 12 12A 13 14 2X 2K C2 Schematic Circui...

Page 231: ...ction E Section E Hydraulics 9803 8500 Issue 3 30 7 30 7 A257372 1 2 3 4 5 6 7 F1 2X M1 P1 P2 M2 P3 8 5A T T S1 C1 2X 9 2A 2B 2C 2D 2E 2F 2G 2X 10 2H 2J F2 S2 11 12 12A 13 14 2X 2K C2 Schematic Circui...

Page 232: ...V 2J Auxiliary Relief Valve ARV 2K One way Restrictor 2X Pressure Test Points 3 Right Hand Joystick 4 Check Valve 8 bar 5 Lift Ram 5A Manually Operated Dump Valve 6 Compensating Ram 7 Crowd Ram 8 Pres...

Page 233: ...Valve ARV 2J Attachment Auxiliary Relief Valves if required 2X Pressure Test Points 3 One way Restrictor 4 Lift Ram 5 Compensating Ram 6 Crowd Ram 7 Filter By pass and Oil Cooler Relief Valve 8 Check...

Page 234: ...Section E Section E Hydraulics 9803 8500 Issue 3 30 10 30 10 A257152 1 2 9 4 5 6 7 F1 2X M1 P1 P2 M2 P3 8 T S1 C1 2X 10 2A 2B 2C 2D 2E 2F 2G 2X 11 2H 2J F2 S2 12 11A 2X C2 3 2J Schematic Circuit...

Page 235: ...nk 1 Loader Joystick 2 Main Loader Valve Block 2A Auxiliary Spool 2B Lift Spool 2C Crowd Spool 2D Main Relief Valve MRV 2E Attachment Auxiliary Relief Valve if required 2F Attachment Auxiliary Relief...

Page 236: ...Loader Joystick 2 Main Loader Valve Block 2A Auxiliary Spool 2B Lift Spool 2C Crowd Spool 2D Main Relief Valve MRV 2E Attachment Auxiliary Relief Valve if required 2F Attachment Auxiliary Relief Valve...

Page 237: ...2B Stelo distributore comando rovescio 2C Stelo distributore comando sollevamento 2D Valvola principale 2E Valvole di sovrappressione ausiliarie se richieste per attrez zatura 2F Valvola ausiliaria 2G...

Page 238: ...ainer S2 High flow Pump Suction Strainer T Tank 1 Brake Valve 2 Main Loader Valve Block 2A Auxiliary Spool 2B Crowd Spool 2C Lift Spool 2D Main Relief Valve MRV 2E Attachment Auxiliary Relief Valves i...

Page 239: ...Assembly up to machine no 676701 1 2 Removal and Replacement 1 2 Dismantling and Assembly 1 4 Wheel Hub Assembly from machine no 676702 1 6 Removal and Replacement 1 6 Dismantling and Assembly 1 6 Tyr...

Page 240: ...fixing 220 Nm 162 lbf ft 22 kgf m Wheels with 6 bolt fixing 405 Nm 298 lbf ft 41 kgf m WARNING A raised and badly supported machine can fall on you Position the machine on a firm level surface before...

Page 241: ...1 2 Section F Transmission 9803 8500 Section F 1 2 Issue 2 Tyres and Wheels 167861 167811...

Page 242: ...e spider see Drive Motor Removal Section E Lift off the appropriate chain from the drive sprocket Note that the front hub is driven by the inner chain therefore the rear chain will need to be lifted o...

Page 243: ...1 4 Section F Transmission 9803 8500 Section F 1 4 Issue 2 Tyres and Wheels 167851...

Page 244: ...before assembly When assembling the sprocket note that it is dished to offset the teeth from the mounting face Therefore on the front hub the sprocket teeth should be furthest from the housing on the...

Page 245: ...1 6 Section F Transmission 9803 8500 Section F 1 6 Issue 1 Tyres and Wheels S255770 A D B C C B 1 2 3 4 4A 5 6 7 8 9 S255780 X X S255790 Y Y Z...

Page 246: ...tension is achieved fit and tighten bolts C and tighten nut B Fit and tighten the second locknut to the adjustment bolt Leave the adjustment bolt in position to prevent any movement of the hub and su...

Page 247: ...Contents Page No Preparation for Towing Winching up to machine number 676354 1 1 from machine number 676355 1 2 Brakes 9803 8500 Issue 2 Section G Section G...

Page 248: ...ent accidental movement when the brakes are released 2 Remove the operator s seat 3 Using an internal hexagonal wrench loosen the four relief valves A on the hydraulic pump by a maximum of four turns...

Page 249: ...ress in the by pass plungers on the four Charge Check valves A underneath the pump This will open the valves and allow oil from the motors to flow freely through the pump The valves will stay open unt...

Page 250: ...Contents Page No Specification Technical Data Peugeot Engine 1 1 Technical Data JCB Diesel Engine 1 2 Removal and Replacement 2 1 Engine 9803 8500 Issue 3 Section K Section K...

Page 251: ...essure hot Model Max rev min Max rev min at loaded speeds 110 C 230 F Robot 150 2630 3000 3 6 bar 52 2 lbf in2 3 7 kgf cm2 Robot 165 2630 3000 3 7 bar 53 7 lbf in2 3 8 kgf cm2 Robot 165 Hi Flow 3600 3...

Page 252: ...Rated Speed 2600 rev min Idling Speed 890 910 rev min Fuel System Injection Pump Type Bosch 104135 4010 Governing Mechanical Static Timing 19 BTDC Injector Codes Bosch 105148 1170 Injector Setting Pr...

Page 253: ...2 1 Section K Engine 9803 8500 Section K 2 1 Issue 1 Removal and Replacement S167990...

Page 254: ...ngine lifting eyes WARNING Lifting Equipment You can be injured if you use faulty lifting equipment Make sure that lifting equipment is in good condition Make sure that lifting tackle complies with al...

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