JCB Robot 160, 170, 180T Skid Steer Loader Repair Service Manual – 9803/8520-14

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This service manual PDF download for the Robot 160, 170, 180T 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: 680001 Onwards
JCB Robot 170, 170HF – S/N: 680001 Onwards
JCB Robot 180T, 180T HF – S/N: 1162000 Onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care & Safety
Section 3 – Routine Maintenance
Section A – Attachments
Section B – Body & 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
P/N : 9803/8520 Iss 14
Total Pages : 308

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 !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Cover
Contents

General Information
Identifying your Machine
Torque Settings
Service Tools
Numerical List
Body and Framework
Electrics
Hydraulics
Transmission
Sealing and Retaining Compounds

Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety
Safety Decals

Routine Maintenance
Fluids, Capacities and Lubricants
Lubricants – Health and Safety
Fuel System
Types of Fuel
Filling the Tank
Service Schedules
Loader Arm Safety Strut
Greasing and Oiling
Body and Framework
Cleaning Cab Interior
Checking Seat Belt Condition and Security
Electrical System
Battery Safety
Warning Symbols
Checking the Electolyte Fluid
Hydraulic System
Checking the Fluid Level
Changing the Filter
Changing the Hydrauic Tank Breather
Transmission
Drive Chain Lubrication
Checking the Oil Levels
Changing the oil Levels
Tyres and Wheels
Inflating the Tyres
Replacing the Segments of Optional Non-Inflatable Tyres
Checking the Wheel Nut Torques
Tyre Table
Engine
Air Filter
Changing the Elements
Checking the Oil Level (up to macine no. 681290)
Changing the Oil and Filter (up to machine no. 681290)
Checking the Oil Level (from machine no. 681291)
Changing the Oil and Filter (from machine no. 681291)
Renewing the Engine Breather (from machine no. 681291)
Changing the In-Line Fuel Filter
Draining the Fuel Filter
Changing the Fuel Filter Element
Bleeding the Fuel System
Cooling System
Coolant Mixtures
Checking the Coolant Level
Changing the Coolant
Cleaning the Coolant Radiator
Adjusting the Alternator Belt
Fitting a New Alternator Belt
Windscreen Washer

Optional Attachments
Quick Release Couplings
Connecting/Disconnecting Hydraulic Hoses
Shovels
General Purpose and Light duty Shovels
6-in-1 Shovel
Pallet Fork
Manure/Silage Fork with Top Grab
Attachment Frame

Body and Framework
Seat and Pump Cover
Seat Removal and replacement
Pump Cover Removal and Replacement
Windows
Front Window Removal and Replacement
Glazing
Cab/Canopy Door – Removal and Replacement
Cab/Canopy – Removal and Replacement
Loader Arm – Removal and Replacement
Rivet Nuts

Electrics
Technical Data
Light Bulbs
Circuit Protection
Sensing Switches
Test Methods
How to Use a Multimeter
How to Measure Voltage
How to Measure Resistance
How to Measure Continuity
How to Test a Diode or a Diode Wire
Problem Solving
Circuit Diagram up to machine no. 681290
Circuit Diagram from machine no. 681291
Optional Air Conditioning circuit
Robot 180T Parking Brake Circuit
Battery Testing
Alternator
General Description
Service Precautions
Charging Circuit Check
Alternator Charging Test
Removal and Replacement
Dismantling and Assembly
Starter Motor
Starting Circuit Test
Removal and Replacement
Harness Diagrams
Wire Number Identification
Harness Structure
Robot 160, 170 Harnesses
Mainframe Harness up to machine no. 681290
Mainframe Harness from machine no. 681291
Panel Harness up to machine no. 681581
Road Light Harness to machine no. 680148
Road Light Harness from machine no 680149 to 681581
Panel Harness without Road Lights from machine no. 681582
Panel Harness with Road Lights from machine no. 681582
Robot 180T Harnesses
Mainframe Harness
Panel Harness without Road Lights
Panel Harness with Road Lights
Park Brake Harness

Controls
Safety Restraint 160/170 – Removal and Replacement
Safety Restraint 180T – Removal and Replacement
Manual Controls
Dismantling and Assembly – General
Manual Control Levers
Manual Control Linkage – Hand Operated Loader
Manual Control Linkage – Foot Operated Loader

Hydraulics
Technical Data
Descriptions
General
Transmission Pump Operation
Servo Transmission Operation
Forward
Reverse
Spin Turn to Right
Neutral High-Flow Machines
Loader Control Valve
Neutral Circuit
Shovel Tilt
Lift Arm Raise
Lift Arm Lower
Power Management System (P.M.S.) fitted||to 180T with Servo Transmission Controls
Towing/Winching
Problem Solving
Transmission
Loader Circuit
Self Levelling Valve
High-Flow Circuit
Power Management System (P.M.S.) fitted||to 180T with Servo Transmission Controls
Schematic Hydraulic Circuit
Servo Wheeled Machines
Standard Circuit – Single Lever Drive Control
High-Flow Circuit – Single Lever Drive Control
Standard Circuit – Dual Lever Drive Control
High-Flow Circuit – Dual Lever Drive Control
Manual Wheeled Machines
Standard Circuit
High-Flow Circuit
Servo Tracked Machines
Standard Circuit
High-Flow Circuit
Manual Tracked Machines
Standard Circuit
High-Flow Circuit
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Contaminant Standards
Filters
Cleaning Operation
Pressure Testing
Main Relief Valve
Power Management System (P.M.S.) fitted||to 180T with Servo Transmission Controls
Pumps – General
Pump/Engine Couplings
Start-Up Procedure
Manual Pump
Removal and Replacement
Return To Idle Controls
Removal and Replacement
Adjustment
Adjusting the Lever Stops for Straight Line Travel
Dismantling and Assembly
Pump Dismantling and Assembly
Trunnion Covers
Shaft Seal
Check Valves
Seperating the Front and rear Pumps
End Caps
Dismantling and Assembly
Charge Pressure Relief Valve
Servo Pump
Removal and Replacement
Dismantling and Assembly
Input Shaft Seal
Output Shaft Cover ‘O’ ring
High Pressure Relief Valves
Charge/Anti-Stall Valve
Charge Pressure Checking and Adjustment
Loader Pump
Removal and Replacement
Dismantling and Assembly – Standard
Dismantling and ASsembly – High Flow
Drive Motors
Motor Unit Removal and Replacement
Motor Unit Dismantling and Assembly
Motors – Tracked Machine
Removal & Replacement
Dismantling & Assembly
Motor Bearing housing removal and Replacement
Motor Bearing Housing Dismantling and Assembly
Valves
Loader Valve – Servo Machine
Removal and Replacement
Dismantling and Assembly up to serial no. 681431
Dismantling and Assembly from serial no. 681432
Loader Valve – Manual Machines
Removal and Replacement
Dismantling and Assembly up to serial no. 681145
Dismantling and Assembly from serial no. 681146
Self Levelling Valve
Removal and Replacement
Dismantling and Assembly
Servo Joysticks
Removal and Replacement
Dismantling and Assembly up to machine no. 680559
Dismantling and Assembly from machine no. 680560
Rams
Removal and Replacement
Loader Arm Lift Ram
Quickhitch Tilt Ram
Dismantling and Assembly
Typical Ram
Hydraulic Filter
Removal and Replacement
Hydraulic Tank
Suction Strainer – Removal and Replacement

Transmission
Description
Tyres and Wheels
Roadwheels – Removal and Replacement
Hubs and Driveshafts
Wheel Hub Assembly (Right Hand)
Removal and Replacement
Dismantling and Aseembly
Left Hand Drive Shaft – Removal and Replacement
Drive Chains
Removal and Replacement
Adjustment

Brakes
Description
Testing the Parking Brake
Adjusting the Parking Brake
Adjusting the Manual Override Lever
Parking Brake Mechanism – Dismantling and Assembly

Tracks
Description
Track Damage
Track Repair
Track Removal & Replacement
Idler Wheels & Rollers
Removal & Replacement
Front Idler Wheel & Recoil Unit Dismantling & Assembly
Rear Idler Wheel Dismantling & Assembly
Guide Roller Dismantling & Assembly
Track Frame Removal & Replacement

Engine
Technical Data
Up to machine no. 681290
From machine no. 681291
Removal and Replacement

 

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JCB Robot 160, 170, 180T Skid Steer Loader Repair Service Manual – 9803/8520-14.pdf

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