JCB Robot 160, 170, 180 Skid Steer Loader Service Manual
355 pages · Publication 9803-9450-1
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What's inside
From the manual's own table of contents: 3 sections, 265 entries. See sample pages (PDF, 403 KB)
General71 topics
- About this Publication
- Machine Model and Serial Number
- Machine Identification Plate
- Typical Product Identification Number (PIN)
- Engine Number
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- Numerical List Section B - Body and Framework
- Tool Detail Reference Section B - Body and Framework
- Numerical List Section C - Electrics
- Tool Detail Reference Section C - Electrics
- Numerical List Section E- Hydraulics
- Tool Detail Reference Section E- Hydraulics
- Sealing and Retaining Compounds
- Safety Notices
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Safety Decals
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Lifting Regulations - Inspections and Tests
- Obtaining Replacement Parts
- Health and Safety
- Lubricants
- Battery
- First Aid - Electrolyte
- Service Schedules
- How to Use the Service Schedules
- Pre-start Cold Checks, Service Points and Fluid Levels
- Functional Test and Final Inspection
- Fluids, Lubricants and Capacities
- Coolant Mixtures
- Cleaning the Machine
- Cleaning the Cab Interior
- Checking for Damage
- Seat Belt
- Checking the Seat Belt Condition and Security
- ROPS/FOPS Structure
- Checking the ROPS/FOPS Structure
- Boom Safety Strut
- Installing
- Removing
- Greasing
- Greasing 10 Hours
- Every 50 Hours
- Oiling
- Every 500 Hours
- Access Panels
- Engine Cover
- Rear Panel
- Electrical System
- Jump Starting the Engine
- Fuses and Relays
- Engine Air Filter
- Changing the Elements
- Cleaning the Air Filter Dust Valve
- Engine
- Checking the Oil Level
- Changing the Oil and Filter
- Checking the Coolant Level
- Changing the Coolant
- Checking the Alternator Belt Tension
- Adjusting the Alternator Belt
Section 3 - Maintenance68 topics
- Fuel System
- Types of Fuel
- Filling the Tank
- Changing the In-line Fuel Filter
- Draining the Fuel Filter
- Changing the Fuel Filter Element
- Bleeding the Fuel System
- Hydraulic System
- Checking the Hydraulic Oil Level
- Changing the Charge Filter Element
- Changing the Return Filter Element
- Drive Chain Lubrication
- Changing the Oil
- Tyres and Wheels
- Tyre Inflation
- Checking the Wheel Nut Torque
- Renewing Segments of Optional Non-Inflatable Tyres
- Tracks
- Track Adjustment
- Windscreen Washer (optional)
- Checking the Level
- General Information
- Quick Release Couplings
- Connecting and Disconnecting
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hoses
- Disconnecting the Hoses
- Shovels
- General Purpose and Light Duty Shovels
- 6-in-1 Shovel
- Pallet Forks
- Daily Maintenance
- Manure/Silage Fork with Top Grab
- Attachment Frame
- Removal and Replacement
- Removal
- Replacement
- Rivet Nuts
- Fitting Procedure
- General Electrical Data
- Light Bulbs
- Sensing Switches
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- Testing
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starting Circuit Test
- Main Components
- Lamps
- Fuses
- Wire and Harness Number Identification
- Wire Numbers and Functions
- Harness Structure
- Drawings and Interconnection
- Harnesses
- Dismantling and Assembling
- Dismantling
- Assembling
Section C - Electrics50 topics
- Dismantling and Assembly
- Servicing
- General Data
- Loader Pump - Standard (P3)
- Loader Pump - High-Flow (P3 and P5)
- Charge Pump (P4)
- Relief Valve Operating Pressures
- Transmission Pump
- Hydraulic Motors - Wheeled Machines
- Hydraulic Motors - Tracked Machines
- Loader Valve Block - Servo Machines
- Loader Valve Block - Manual Machines
- Self Level Valve (optional)
- Filters
- Rams
- Hydraulic Tank
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Neutral Circuits
- Standard Machines
- High-flow Machines
- Loader Circuit
- Transmission Circuit
- Servo Circuits
- Transmission Pump Operation
- Charge Pressure
- High Pressure Relief Valves
- Transmission Motor Operation
- Loop Flushing System
- Speed Operation (optional)
- Servo Transmission Operation
- Neutral
- Forward
- Reverse
- Right Spin Turn
- Loader Valve Operation
- Neutral Circuit
- Shovel Tilt
- Lift Arm Raise
- Lift Arm Lower
- Self Level Valve
- Loader Arm Raise - Self Levelling
- Tilt Ram Fully Extended
- Loader Arm Lower
- Tilt Ram Extend
- Tilt Ram Retract
- Power Management System (P.M.S.)
- Operation
Section E - Hydraulics73 topics
- Hydrostatic Transmission
- Checking for Faulty Pump or Motor
- Checking Wheel Speed
- Machine Veers to One Side when Travelling
- Transmission Pump Neutral Adjustment
- Checking Motor Leakage Rate
- Pump Main Relief Pressure Test Points
- Testing Main Relief Valves
- Checking the Joystick Hydraulic Lines
- Levelling Circuit
- High-flow Circuit
- Checking Flow and Pressure
- Warning Light Indications
- System Check
- Fault Tracing
- General
- Bleeding the Hydraulic System
- Standard and High-flow Servo Machines
- Component Key
- Control Variations
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Procedure
- Loader Main Relief Valve (M.R.V.)
- Transmission Charge Pressure
- Calibration Procedure
- To fit Sensitivity Control to Non High Flow Machines
- Pump/Engine Coupling
- Input Shaft Seal
- Output Shaft Cover ‘O’ Ring
- Charge Valve
- Start-Up Procedure
- Typical Loader Pump
- Loader Pump - Standard Machines
- Loader Pump - High-flow Machines
- Motors - Wheeled Machine
- Inspection
- Assembly
- Motor Bearing Housing
- Motors - Tracked Machine
- Brake Dismantling and Assembly
- Motor Dismantling
- Reassembling
- Loader Valve - Servo Machines
- Hose Connections
- Loader Valve - Manual Machines
- Servo Cut-off Valve
- Brake and Power Management System (P.M.S.) Dump Valve
- Float Valve
- Loader Arm Lift Ram
- Quickhitch Tilt Ram
- Typical Ram
- When Dismantling
- When Assembling
- New rod and piston head
- New piston head fitted to a pre-drilled piston rod
- New piston rod fitted to a pre-drilled piston head
- JCB Ram Sealing Procedure
- Drive Train
- Tracked machines
- Roadwheels
- Wheel Hub Assembly (right hand)
- Drive Shaft Assembly (left hand)
- Adjustment
- Description
- Types of Rubber Track Damage
- Recommended Repair Procedures
- Front Idler Wheel and Recoil Unit
- Rear Idler Wheel
- Guide Roller
Inside this manual
Real pages from this service manual (355 pages). Open the sample pages (PDF, 402 KB)
- Specifications, page 67: Section 3 - Maintenance
- Troubleshooting, page 147: Section C - Electrics
- Diagram, page 202: Operation Description
- Color page, page 330: Section J - Tracks
- Color page, page 219: Section E - Hydraulics
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 355 pages
Quantity one is the manual described above.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).