jcb ROBOT 150 User manual

Service
Manual
ROBOT
150, 165
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER [phone]
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
R

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=General Information - includes torque settings and service tools.
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 remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A=Attachments
B=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

i
Contents Page 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 1
i
Issue 1

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 Ais located as shown. It is
stamped with the serial numbers of the major individual units.
Typical Vehicle Identification Number (VIN)
SLP 165 S B V E 677001
World Manufacturer Identification
Machine Model
Machine Type (S = Standard, H = High-flow)
Build Type (A = Canopy, B = Cab)
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
Section 1
1 - 1
Issue 5
Identifying your Machine
AA
S173720
CONSTRUCTOR MADE IN UK
J.C.BAMFORD EXCAVATORS LTD.
ROCESTER, STAFFS, ENGLAND.
R
Vehicle Identification No. Product Identification No.
ENGINE SERIAL No. WEIGHT
PUMP SERIAL No. YEAR OF MANUFACTURE
MODEL 80/1269/EEC MODEL 80/1269/EEC
POWER KW R.P.M. POWER KW R.P.M.
150
165
165 HF
1CX
1CX HF
185
185 HF
35
35
35
35
35
52
52
2800
2800
2800
2800
2800
2200
2200
817/04437
11223344556677
11
22
33
44
55
66
77

1 - 2
Unit Identification
The engine serial number on XUD engines is stamped on a
machined area Bon the top of the cylinder block. On JCB
Diesel engines the number is stamped on a label Gon 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.
The lift arm serial number 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, 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.
Left Side, Right Side
In this manual, 'left' Xand 'right' Ymean your left and right
when you are seated correctly in the machine.
Section 1 General Information
9803/8500
Section 1
1 - 2
Issue 2*
Identifying your Machine
Y
XS173660
BB
DD
S173730
S173750
S255430
GG
EE
S173760
CC
FF
S173742
*

2 - 1
Section 1 General Information
9803/8500
Section 1
2 - 1
Issue 2*
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 Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
1/4(6.3) 7/16 14 1.4 10
5/16 (7.9) 1/228 2.8 20
3/8(9.5) 9/16 49 5.0 36
7/16 (11.1) 5/878 8.0 58
1/2(12.7) 3/4117 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) 11/8407 41.5 300
7/8(22.2) 15/16 650 66.3 480
1 (25.4) 11/2970 99.0 715
11/4(31.7) 17/81940 198.0 1430
11/2(38.1) 21/43390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
*

3 - 1
Numerical List
Page No.
1406/0011 Bonded Washer 4 - 3
1406/0018 Bonded Washer 4 - 3
1406/0021 Bonded Washer 4 - 2/4 - 3
1406/0029 Bonded Washer 4 - 3
1604/0003 Adapter 4 - 3
1604/0004 Adapter 4 - 3
1604/0006 Adapter 4 - 2/4 - 3
1606/0003 Adapter 4 - 3
1606/0004 Adapter 4 - 3
1606/0007 Adapter 4 - 3
1606/0008 Adapter 4 - 3
1606/0009 Adapter 4 - 3
1612/0006 Adapter 4 - 2
4101/0251 Threadlocker and Sealer 5 - 1
4101/0451 Threadlocker 5 - 1
4101/0552 Threadlocker and Sealer (High Strength)5 - 1
4101/0651 Retainer (High Strength) 5 - 1
4102/0551 High Strength Threadlocker 5 - 1
4102/1201 Multi-Gasket 5 - 1
4104/0251 Activator (Aerosol) 5 - 1
4104/0253 Activator (Bottle) 5 - 1
4104/1557 JCB Cleaner/Degreaser 5 - 1
816/00189 Blanking Cap 4 - 4
816/00190 Blanking Cap 4 - 4
816/00193 Blanking Cap 4 - 4
816/00196 Blanking Cap 4 - 4
816/00197 Blanking Cap 4 - 4
816/00294 Blanking Cap 4 - 4
816/15118 Pressure Test Adapter 4 - 2
816/20008 Adapter 4 - 2
816/50043 'T' Adapter 4 - 4
816/55038 Pressure Test 'T' Adapter 4 - 2
816/55040 Pressure Test 'T' Adapter 4 - 2
816/60096 'T' Adapter 4 - 4
892/00047 'T' Adapter 4 - 4
892/00048 'T' Adapter 4 - 4
892/00055 Blanking Plug 4 - 4
892/00056 Blanking Plug 4 - 4
892/00057 Blanking Plug 4 - 4
892/00059 Blanking Plug 4 - 4
892/00060 Blanking Plug 4 - 4
892/00074 Female Connector 4 - 4
892/00075 Female Connector 4 - 4
892/00077 Female Connector 4 - 4
892/00137 Hose 4 - 3
892/00223 Hand Pump 4 - 3
892/00252 A.R.V 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
892/00259 Pressure Test Adapter 4 - 2
892/00260 Pressure Test Adapter 4 - 2
892/00261 Pressure Test Adapter 4 - 2
892/00262 Pressure Test 'T' Adapter 4 - 2/4 - 3
892/00263 Pressure Test 'T' Adapter 4 - 2
892/00264 Pressure Test 'T' Adapter 4 - 2
892/00265 Pressure Test 'T' Adapter 4 - 2
Page No.
892/00268 Flow Monitoring Unit 4 - 2
892/00269 Sensor Head 4 - 2
892/00270 Load Valve 4 - 2
892/00271 Adapter 4 - 2
892/00272 Adapter 4 - 2
892/00274 Adapter 4 - 3
892/00275 Adapter 4 - 2
892/00276 Adapter 4 - 2
892/00277 Adapter 4 - 2
892/00278 Gauge 4 - 3
892/00279 Gauge 4 - 3
892/00281 AVO Meter 4 - 1
892/00282 Shunt 4 - 1
892/00283 Tool Kit Case 4 - 1
892/00284 Tachometer 4 - 1
892/00285 Hydraulic Oil Temperature Probe 4 - 1
892/00286 Surface Temperature Probe 4 - 1
892/00706 Test Probe 4 - 3
892/00858 Pump Support Bracket 4 - 3
892/00923 A.R.V Test Block - Commercial Hyd. 4 - 3
992/09300 Spanner 4 - 3
992/09400 Spanner 4 - 3
992/09500 Spanner 4 - 3
992/09600 Spanner 4 - 3
993/68100 Slide Hammer 4 - 4
993/85700 Battery Tester 4 - 1
993/99510 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 4 - 2
892/00202 Replacement Gauge 4 - 2
892/00203 Replacement Gauge 4 - 2
892/00254 Replacement Hose 4 - 2
Section 1 General Information
9803/8500
Section 1
3 - 1
Issue 8*
Service Tools
*
*
*
*
*
*
*
*

4 - 1
Section 1 General Information
9803/8500
Section 1
4 - 1
Issue 2*
Service Tools
Section C - Electrics
AVO Test Kit
1892/00283 Tool Kit Case
2892/00281 AVO Meter
3892/00286 Surface Temperature Probe
4892/00284 Microtach Digital Tachometer
5892/00282 Shunt - open type
6892/00285 Hydraulic Oil Temperature Probe
* 993/85700 Battery Tester
188230
239510

Pressure Test 'T' Adapters
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSPP x Test Point
Pressure Test Adapters
892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Flow Test Equipment
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 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP
4 - 2
Section E - Hydraulics
Section 1 General Information
9803/8500
Section 1
4 - 2
Issue 2*
Service Tools
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 Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254 Replacement Hose
188120
*
200140
188150
188130

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4 - 2
Maintenance Safety (cont'd)
!!WARNING
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
cream or wear gloves to prevent skin contact. Wash skin
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
!!WARNING
Soft Ground
A machine can sink into soft ground. Never work under a
machine on soft ground.
INT-3-2-4
!!WARNING
Tyres and Rims
Over-inflated or over-heated tyres can explode. Follow the
instructions in this manual for inflating the tyres. Do not weld
or cut rims. Get a tyre/wheel specialist to do any repair work.
INT-3-2-6
!!WARNING
Fires
If your machine is equipped with a fire extinguisher, make
sure it is checked regularly. Keep it in the operator's cab until
you need to use it. Do not use water to put out a machine
fire, you could spread an oil fire or get a shock from an
electrical fire. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department as
quickly as possible. Firefighters should use self-contained
breathing apparatus.
INT-3-2-7/1
!!WARNING
Hot Coolant
The cooling 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 first notch and let the steam
pressure escape, then remove the cap.
INT-3-2-9
!!CAUTION
Rams
The efficiency of the rams will be affected if they are not kept
free of solidified dirt. Clean dirt from around the rams
regularly. When leaving or parking the machine, close all
rams if possible to reduce the risk of weather corrosion.
INT-3-2-10
!!CAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
!!CAUTION
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
!!WARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers
Kinked or crushed hoses
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
!!WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This will
protect against eye injury from components accidentally
flying out.
GEN-6-2
Section 2 Care and Safety
9803/8500
Section 2
4 - 2
Issue 2

5 - 1
Safety Decals
!!WARNING
Decals on the machine warn you of particular hazards. Each
decal is attached close to a part of the machine where there
is a possible hazard. Read and make sure you understand
the safety message before you work with or on that part of
the machine.
Keep all decals clean and readable. Replace lost or
damaged 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
!!WARNING
If you need eye-glasses for reading, make sure you wear
them when reading the safety decals. Decals are
strategically placed around the machine to remind you of
possible hazards. Do not over-stretch or place yourself in
dangerous positions to read the decals.
INT-3-3-4
Section 2 Care and Safety
9803/8500
Section 2
5 - 1
Issue 2