JCB Robot 150, 165 Skid Steer Loader Service Manual – 9803/8500-1

(S/N: 678000 Onwards)
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This workshop repair service manual PDF download for the Robot 150, 165 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 150 – S/N: 678000 Onwards
JCB Robot 165, 165HF – S/N: 678000 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 K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/8500-1
Total Pages : 254

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.

More Info : http://www.sitelux.com

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Cover
Contents

General Information
Identifying your Machine
Torque Settings
Service Tools
Numerical List
Electrics
Hydraulics
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
Service Schedules
Loader Arm Safety Strut
Greasing
Body and Framework
Oiling
Cleaning Cab Interior
Checking Seat Belt Condition and Security
Electrical System
Battery Safety
Checking the Electrolyte Level
Changing the Light Bulbs
Hydraulic System
Checking the Fluid Level
Changing the Filter
Transmission
Drive Chain Lubrication up to machine number 677999
Checking the Oil Levels
Changing the Oil
Drive Chain Lubrication from machine number 678000
Checking the Oil Levels
Changing the Oil
Adjusting the Drive Chain Tension
Tyres and Wheels
Inflating the Tyres
Replacing Segments of Optional Non-inflatable Tyres
Checking the Wheelnut Torques
Tyre Table

Optional Attachments
Quick Release Couplings
Connecting/Disconnecting Hydraulic Hoses
Shovels
General Purpose and Light Duty Shovels
6-in-1 Shovel
Pallet Forks
Manure/Silage Fork with Top Grab
Attachment Frame
Backhoe Attachment
Technical Data
Routine Maintenance
Circuit Description
Valve Block – Removal and Replacement
Valve Block – Dismantling and Assembly
Pressure Testing
Carriage Clamp Mechanism
Stabilisers
Dipper & Boom – Removal and replacement
Ram – Removal and Replacement
Ram – Dismantling and Assembly

Body and Framework
Seat and Floor Plate
Seat – Removal and Replacement
Floor Plate – Removal and Replacement
Glazing
Front Window – Removal and Replacement
Rear Window – Removal and Replacement
Side Window – Removal and Replacement
Door – Removal and Replacement
Loader Arm – Removal and Replacement

Electrics
Technical Data
Light Bulbs
Circuit Protection
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
Battery
Testing – Specific Gravity
Battery Testing
Alternator
General Description
Service Precautions
Charging Circuit Check
Alternator Charging Test
Removal and Replacement
Peugeot Engines
Perkins Engines
Dismantling and Assembly
Starter Motor
Starting Circuit Test
Removal and Replacement
Circuit Diagrams
Up to machine no. 675357
From Machine no. 675358 to 677000
From machine no. 677001
Basic Canopy – servo controls
Cab + Options – servo controls
Basic Canopy – Manula controls
Cab + Options – manual controls

Controls
Safety Restraint Bar
Description
Removal and Replacement
Locking Mechanism
Removal and Replacement
Adjustment
Throttle Controls
Description
Removal and Replacement
Adjustment
Throttle Cable
Removal and Adjustment
Adjusting the Idle and Non-Stalling Settings

Hydraulics
Technical Data up to machine number 677000
Technical Data from machine no. 677001 to 677999
Technical Data from machine no. 678000
General Description
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminent Standards
Filters
Descriptions
Machine Neutral Circuit
Auxiliary Gear Pump
Loader Valve Neutral Circuit
Lift Ram Operation
Crowd Ram Operation
Load Hold Check Valves
Relief Valve Operation
Pressure Reducing Solenoid Valve
Drive Motor Operation
Transmission Operation
Neutral
Forward
Pumps
Removal and Replacement
Pump/Engine Couplings
Start-Up Procedure
Hydrostatic Pump, servo up to machine no. 676354, and manual
Dismantling and Assembly
Trunnion Covers
Shaft Seal
Check Valves
Seperating the Front and Rear Pumps
Main Pump Endcaps
Dismantling and Assembly
Charge Pressure Relief Valve
Main Pumps – Dismantling and Assembly
Control Adjustment – Manual Machines
Hydrostatic Pump, servo from machine no. 676355
Removal and Replacement – Shaft Seal
Dismantling and Assembly
Charge Check and High Pressure Relief Valves
Charge/Anti-Stall Valve
Charge Pressure Adjustment
Pump Neutral Adjustment
Auxiliary Pump
Removal and Replacement
Dismantling and Assembly – Standard
Dismantling and Assembly – High Flow
Drive Motors
Removal and Replacement
Drive Sprocket
Motors
Dismantling and Assembly
Motors up to machine no. 676354
Motors from machine no. 676355
Problem Solving
Hydrostatic Transmission
Problems, Causes and Remedies
Checking for Faulty Pump or Motor
Checking Wheel Speed
Machine Veers to one Side When Travelling
Checking Motor LEakage Rate
Pump Main Pressure Test Points
Checking Brake Circuit Pressure
Checking the Joystick Hydraulic Lines
Valves
Loader Valve – Removal and Replacment
Loader Vavle up to machine no. 677000
Dismantling and Assembly
Main Relief Valve and Auxiliary Relief Valves
Removal, Replacement, Dismantling and Assembly
Pressure Testing – Main Relief Valve
Pressure Testing – Auxiliary Relief Valve
Loader Valve from machineno. 677001
Dismantling and Assembly – Valve and Manual Spool
Dismantling and Assembly – Servo Spool
Dismantling and Assembly – Solenoid Spool
Main Relief Valve and Auxiliary Relief Valves
Removal, Replacement, Dismantling and Assembly
Pressure Testing – Main Relief Valve
Pressure Testing – Auxiliary Relief Valve
Check Valve
Pressure Reducing Solenoid Valve (up to machine no. 677999)
Brake Valve (from machine no. 678000)
Servo Joysticks
Removal and Replacement
Dismantling and Assembly
Rams
Removal and Replacement
Lift and Compensating Ram
Crowd Ram
Dismantling and Assembly – Typical Ram
Hydraulic Filter – Removal and Replacement
Hydraulic Tank
Suction Strainer – Removal and Replacement
Schematic Hydraulic Circuit
Servo Machines up to serial no. 675573
Servo Machines from serial no. 675574 to 677000
Servo machines from serial no. 677001 to 677999
Single Drive Lever Control
Dual Drive Lever Control
Manual Machines from serial no. 677001 to 677999
Servo Machines from serial no. 678000
Standard Circuit
High Flow Circuit
Manual Machines from serial no. 678000
Standard Circuit
High Flow Circuit

Transmission
Tyres and Wheels
Roadwheels – Removal and Replacement
Wheel Hub Assembly up to machine no. 676701
Removal and Replacement
Dismantling and Assembly
Wheel Hub Assembly from machine 676702
Removal and Replacement
Dismantling and Assembly

Brakes
Preparation for Towing/Winching
up to machine no. 676354
from machine no. 676355

Engine
Specification
Technical Data – Peugeot Engine
Technical Data – JCB Diesel Engine
Removal and Replacement

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