JCB 165 165HF Robot Workshop Repair Service Manual

Service Manual ROBOT 150, 165 PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © 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 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 A is 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 A S173720 CONSTRUCTOR MADE IN UK J.C.BAMFORD EXCAVATORS LTD. ROCESTER, STAFFS, ENGLAND. 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 1 2 3 4 5 6 7 1 2 3 4 5 6 7

1 - 2 Unit Identification The engine serial number on XUD engines is stamped on a machined area B on the top of the cylinder block. On JCB Diesel engines the number is stamped on a label G on 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' X and 'right' Y mean 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 X S173660 B D S173730 S173750 S255430 G E S173760 C F 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 /2 28 2.8 20 3 /8 (9.5) 9 /16 49 5.0 36 7 /16 (11.1) 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) 1 1 /8 407 41.5 300 7 /8 (22.2) 1 5 /16 650 66.3 480 1 (25.4) 1 1 /2 970 99.0 715 1 1 /4 (31.7) 1 7 /8 1940 198.0 1430 1 1 /2 (38.1) 2 1 /4 3390 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 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 6 892/00285 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/in 2 ) 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in 2 ) 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in 2 ) 892/00254 Replacement Hose 188120 * 200140 188150 188130

JCB 165 165HF Robot Workshop Repair Service Manual

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